GDW Tow Bar Installation Guide
Opel Astra GTC 3D (2005 onwards)
Model Reference: 1521
Product Information
This document provides installation instructions, technical specifications, and component details for the GDW tow bar system (Reference 1521) designed for the Opel Astra GTC 3D, model year 2005 and later.
EEC Approval Number: e6*94/20*0539*00
Technical Specifications:
- D-Value: Calculated based on maximum towing weight and vehicle specifications, with a maximum limit of 8.75 kN.
- S-Value (Vertical Load): Maximum 75 kg.
- Maximum Towing Capacity: 1600 kg.
Manufacturer: GDW nv
Address: Hoogmolenwegel 23, B-8790 Waregem
Contact: TEL. +32 (0) 56 60 42 12, FAX. +32 (0) 56 60 01 93, Email: gdw@gdwtowbars.com, Website: www.gdwtowbars.com
Tow Bar Assembly Overview
The tow bar assembly, identified as Ref. 1521, is designed to be mounted to the vehicle's chassis at specific points labeled A, B, C, and D. The system includes a ball and socket assembly, identified as the T36 Escamotable type.
Installation Instructions
Follow these steps for proper installation:
- Remove the floor covering and interior trim from the trunk area, and then disassemble the rear bumper.
- Drill the pre-existing holes on the underside of the chassis (identified by an indentation in the trunk) using a 10.5mm drill bit. Enlarge only the top plate of these holes to 25mm. Insert the distance tubes (part 3 and 4) through these 25mm openings into the chassis beam. Remove any protective coating (e.g., bitumen) from the areas where the tow bar components will be attached. Place the counter plates (part 1 and 2) onto the mounting tubes and insert the bolts.
- Position the tow bar assembly against the underside of the chassis, aligning it with the provided holes at points (A), (B), (C), and (D). Install washers and nuts, then securely tighten all fasteners according to the specified torque values.
- Reassemble the bumper.
- Mount the ball and socket assembly together with the safety shackle, ensuring all components are securely tightened according to the specified torque values.
Important Notes:
- For the maximum permissible towing mass for your vehicle, consult your vehicle dealer or owner's manual.
- Remove any bitumen coating or anti-rattle material from the fastening points on the chassis before installation.
- Exercise caution during drilling to avoid damaging any brake lines, electrical wiring, or fuel lines.
Parts List
| Part Number | Description | Quantity | Attachment Points |
|---|---|---|---|
| 1521 | Tow bar assembly | 1 | |
| T45L035 | Ball and socket assembly | 1 | |
| DIN931 | Bolts M12x70 | 2 | |
| DIN931 | Bolts M12x65 | 2 | |
| DIN985 | Lock nuts M12 | 4 | |
| T45 | Mounting tubes | 2 | |
| T45 | Mounting pieces | 2 | |
| 800.000 | Safety shackle | 1 | |
| DIN931 | Bolts M10x90 | 4 | (A-B-C-D) |
| DIN934 | Nuts M10 | 4 | (A-B-C-D) |
| DIN128A | Lock washers M10 | 4 | (A-B-C-D) |
| Tubes ø25x5.6x55mm (4) | 2 | (C-D) | |
| Tubes ø25x5.6x60mm (3) | 2 | (A-B) | |
| Washers 40x35x12x4mm | 2 | (C-D) | |
| Mounting piece (2) | 1 | (C-B) | |
| Mounting piece (1) | 1 | (A-D) |
All bolts and nuts used in this assembly are quality 8.8.
Torque Specifications
| Bolt Size | Standard / Quality | Torque (Nm) | Torque (kgm) |
|---|---|---|---|
| M6 | DIN 912, 931, 933, 7991 | 10.8 | 1.1 |
| M8 | DIN 912, 931, 933, 7991 | 25.5 | 2.60 |
| M10 | DIN 912, 931, 933, 7991 | 52.0 | 5.30 |
| M12 | DIN 912, 931, 933, 7991 | 88.3 | 9.0 |
| M14 | DIN 912, 931, 933, 7991 | 137 | 14.0 |
| M16 | DIN 912, 931, 933, 7991 | 211.0 | 21.5 |
| M6 | Quality 10.9 | 13.7 | 1.4 |
| M8 | Quality 10.9 | 35.3 | 3.6 |
| M10 | Quality 10.9 | 70.6 | 7.20 |
| M12 | Quality 10.9 | 122.6 | 12.5 |
| M14 | Quality 10.9 | 194 | 19.8 |
| M16 | Quality 10.9 | 299.2 | 30.5 |
Clearance and Vehicle Weight Information
The clearance specifications must conform to Supplement VII, diagram 30 of guideline 94/20/EG.
Diagram Description: The diagrams illustrate critical clearance dimensions and angles for the tow bar installation. Key measurements include:
- Maximum angle from the vehicle's center line: 45 degrees.
- Maximum distance from the vehicle's rear: 100 mm.
- Minimum clearance from the ground: 140 mm.
- Minimum clearance from the chassis: 65 mm.
- Minimum clearance from the rear axle: 32 mm.
- Minimum clearance from the tow ball center: 55 mm.
- Additional diagrams show clearance angles and radii, with values such as a maximum of 30°, a minimum of 75°, and maximum radii of R14.5 and R40.
- Vertical clearance dimensions are indicated between 350 mm and 420 mm.
The following information pertains to permissible vehicle weights:
For permissible total laden weight of the vehicle.
Pour poids total en charge autorisé du véhicule.
Bij toelaatbaar totaal gewicht van het voertuig.
Bei zulässigem Gesamtgewicht des Fahrzeuges.
