TVW 624 Volkswagen Caddy/Caddy Life/Shuttle 2004> Caddy Maxi 2008>
Parts List
| Item | Qty | Description | Item | Qty | Description |
|---|---|---|---|---|---|
| A | 1 | Crossmember | E | 2 | M16 x 50 Bolts, Nuts & S/P Washers |
| B | 1 | L/H Side Arm | F | 2 | M12 x 85 Grade 10.9 Bolts & Nyloc Nuts |
| C | 1 | R/H Side Arm | G | 4 | M12 x 40 Bolts, Nuts & S/P Washers |
| D | 1 | Extension Bar | H | 2 | M12 Nuts & S/P Washers |
| J | 4 | M10 x 30 Bolts & S/P Washers | |||
| K | 4 | 12 x 35 Flat Washers | |||
| L | 4 | 10 x 40 Flat Washers | |||
| M | 14 | 12 x 25 Flat Washers | |||
| N | 1 | Bumper Insert | |||
| R | 4 | M6 x 15 Bolts, 6 x 20 Flat Washer & S/P Washers | |||
| S | 2 | M6 Nut Clip |
Installation Instructions
- Remove rear bumper. Seven fixings securing the bumper beam to the rear panel, (Remove rubber bung to gain access to the right hand outer fixing.) Three fixings around each wheel arch.
- Cut a section from the lower edge of the bumper 65mm wide x 35 mm deep (CADDY LIFE & MAXI DO NOT NEED ANY BUMPER CUT). If required trim to suit.
- Remove the four fixings securing the bumper beam to the plastic bumper. (Bumper beam is not refitted with the towbar.)
- Locate Item B and Item C into the open ends of each chassis member and using Item J with Item L loosely bolt through existing holes.
- Locate Item A onto the existing studs on the rear panel, loosely bolt using original nuts.
- Using Item H loosely bolt Item A to Item B and Item C.
- Using the hole in the towbar as a jig drill out the left hand outside upper hole to 13mm.
- Using Item G with Item K bolt Item A at the outer top points.
- Fully tighten all nuts and bolts and ensure the towbar is rigid and secure.
- Using Item R bolt Item N to the inside of the bumper Please note the inner bumper reinforcing fillets may need to be removed.
- Refit the bumper using Item G with Item M and Item K through the lower Towbar mounting point.
- Using Item F with Item M bolt Item D to Item A.
- Using Item E bolt the ball bracket and wiring plate (not supplied in this kit) to the mounting plate.
Diagram Description
The diagram illustrates the assembly of the TVW624 towbar system. It shows an exploded view of the main crossmember (A), left-hand (B) and right-hand (C) side arms, and an extension bar (D). Various fasteners including bolts, nuts, and washers (E, F, G, H, J, K, L, M, N, R, S) are depicted with their corresponding connection points on the towbar components and the vehicle's chassis/bumper area. The diagram indicates that the towbar attaches to the vehicle's rear chassis members and existing studs on the rear panel. A specific cut-out area on the "BUMPER LOWER EDGE" is highlighted, with a note that Caddy Life and Maxi models may not require this cut. Part N, the Bumper Insert, is shown being fitted internally. The key "X= Original Fixings" clarifies where existing vehicle mounting points are utilized.
Notes
1. Recommended Torque Setting for M12 Grade 10.9: 139 Nm. (For other Torque Settings see notes overleaf.) 2. Nose load limits and vehicle manufacturers trailer / caravan weight limits must be observed.
