Tow-Trust Towbars
TC647HK Towbar Installation Guide
For Citroen C4 Picasso (5 & 7 Seater, 2006 onwards) and Peugeot 5008 (2010 onwards)
Issue 5
Parts List
| Item | Qty | Description | Item | Qty | Description |
|---|---|---|---|---|---|
| A | 1 | Crossmember | E | 3 | M12 x 22 Bolts & S/P Washers |
| B | 1 | L/H Side Arm | F | 1 | M12 x 25 Bolts & S/P Washers |
| C | 1 | R/H Side Arm | G | 6 | M12 x 40 Bolts, Nuts & S/P Washers |
| D | 1 | Detachable Housing | H | 4 | M10 x 50 Grade 10.9 Bolts & S/P Washers |
| J | 4 | M10 Nyloc Nuts | |||
| K | 4 | 10 x 25 Flat washers | |||
| L | 4 | 10 x 30 Flat Washers | |||
| M | 10 | 12 x 25 Flat Washers | |||
| P | 1 | Socket plate 1 |
Assembly Diagram Overview
The towbar kit (Model TC647HK) comprises a main crossmember (A), left-hand side arm (B), right-hand side arm (C), and a detachable housing unit (D). Various fixings are included: M12 bolts and washers (E, F, G), M10 Grade 10.9 bolts (H), M10 Nyloc nuts (J), and M12 washers (K, L, M). A socket plate (P) is also part of the kit. The diagram illustrates how the side arms (B, C) attach to the chassis and rear panel, and how the crossmember (A) connects to the side arms. It also specifies the use of different mounting holes (1, 2, 3) depending on the vehicle variant: holes 1 & 2 for the C4 5-seater, and holes 1 & 3 for the C4 7-seater. The diagram shows the left and right arms with their respective attachment points and hardware.
Bumper Removal
This towbar can be fitted without removing the bumper, but the fitter may choose to do so.
5 Seat Version Bumper Removal
- Temporarily remove the black plastic from the side of each light cluster to expose the two T20 torx fixings either side. Pull light clusters rearward and disconnect each plug.
- Locate torx fixing and M10 nut at the top of bumper and unscrew.
- Remove from the underside the four fixings either side securing the black plastic to the bumper.
- Remove the three T30 torx fixings and one M8 plastic nut around each wheel arch. Top fixing is hidden where the bumper meets the rear wing.
- Pull bumper outwards at each side until tabs are out.
7 Seat Version Bumper Removal
- Remove light clusters. Three T20 torx fixings. Pull light rearward and disconnect plug. (This reveals two fixings under light.)
- Remove four fixings either side from bottom of bumper to release corner carpets.
- Remove remaining two torx fixings from bottom of bumper.
- Remove two torx fixings securing wheel arch carpet.
- Remove one torx fixing behind wheel arch.
- Remove remaining two top fixings.
- Pull bumper out sideways to release tabs.
Installation Procedure
- Remove the two bottom bolts each side securing bumper crash beam to rear panel.
- Remove exhaust rubber.
- Remove two M10 nuts either side from bottom face of chassis studs, removing black brackets. (Note: on 7 Seater exhaust hanger will not be refitted.)
- Using Item J (Nyloc Nuts) with Item L loosely bolt Items B and C to existing studs on chassis. (Note: on 7 Seater exhaust rubber is refitted to Item C.)
- Using Item H with Item K bolt Items B and C to the rear panel.
- Using Item G with Item M bolt Item A to Items B and C.
- Using Item F with Item M and item E with item M bolt Item D and Item P to Item A.
- Fully tighten all nuts and bolts and ensure the towbar is square, rigid and secure.
- Refit bumper using original fixings. Replace light clusters.
Bumper Cut Dimensions
Peugeot 5008: 80mm WIDE X 55mm DEEP
Important Notes
1. Recommended Torque Setting for M12 Grade 10.9 bolts is 139 Nm. (For other Torque Settings see notes overleaf.)
2. Nose load limits and vehicle manufacturer's trailer / caravan weight limits must be observed.
