Parts List
| Item | Qty | Description | Item | Qty | Description |
|---|---|---|---|---|---|
| A | 1 | Crossmember | G | 2 | M16 x 50 Bolts, Nuts & S/P Washers |
| B | 1 | L/H Side Arm | H | 2 | M12 x 100 Bolts, Nut & S/P Washers |
| C | 1 | R/H Side Arm | J | 2 | M12 x 110 Bolts, Nuts & S/P Washers |
| D | 4 | Clamp Plates | K | 4 | M12 x 40 Bolts, 2 Nuts & 4 S/P Washers |
| E | 2 | 19mm x 59mm Spacer Bushes | L | 4 | 12 x 40 Flat Washers |
| F | 2 | 19mm x 64mm Spacer Bushes | M | 6 | 12 x 25 Flat Washers |
| N | 2 | Rivets |
General Notes
NOTE: There are two sets of holes in the side arms. These are so you can fit the towbar as snug as possible to the back panel (due to model variants).
Installation Instructions
- Remove the rear bumper. It is typically secured by one tip fixing, two fixings at the bottom of the wheel arch, two fixings along the lower edge, and two fixings under the rear light.
- Disconnect rear parking sensors, if fitted.
- Remove the bumper beam. This part is not refitted with the towbar. Replace existing bolts if necessary.
- Mark out and cut open the ends of each chassis member as shown in the diagram. Note: It is recommended to paint the cut ends of each chassis after cutting to prevent corrosion.
- Lower the exhaust system. Note: Support the exhaust to prevent damage during this process.
- Drill out the rearmost rivet securing the heat shield.
- Locate the dimples at the rear of the boot and existing forward holes. Enlarge these holes to 20mm.
- Locate Item B (L/H Side Arm) and Item C (R/H Side Arm) into the open end of each chassis member.
- Place Item E (19mm x 59mm Spacer Bushes) into the rear holes and Item F (19mm x 64mm Spacer Bushes) into the forward holes of each chassis. Using Item H (M12 x 100 Bolts) for the rear holes and Item J (M12 x 110 Bolts) for the forward holes, along with Item D (Clamp Plates), loosely bolt each side arm into place.
- Using Item K (M12 x 40 Bolts) with Item M (12 x 25 Flat Washers) and nuts, bolt Item A (Crossmember) to Item B and Item C. Push Item A as close to the rear panel as possible.
- Fully tighten all nuts and bolts. Ensure the towbar is rigid and secure.
- Using Item N (Rivets), rivet the heat shield back into place through its original hole.
- Replace the exhaust system.
- Cut a small section from the lower edge of the bumper, measuring 20mm x 155mm.
- Replace the rear bumper.
- Using Item G (M16 x 50 Bolts, Nuts & S/P Washers), bolt the ball bracket and wiring plate (not supplied in this kit) to the mounting plate.
Diagrams and Visuals
The main diagram shows an exploded view of the Tow-Trust TMZ2 towbar assembly being fitted to the chassis of a Mazda 6 Hatchback (2002-2008). It illustrates the placement of various components including the crossmember (A), side arms (B, C), clamp plates (D), spacer bushes (E, F), and fasteners (G, H, J, K, L, M, N). The diagram also indicates where the chassis requires cutting (CHASSIS CUT) and the required bumper cutout (BUMPER CUTOUT CENTRED ON VEHICLE).
The "CHASSIS CUT" illustration provides dimensions for the cutouts on the Left Hand (LH) and Right Hand (RH) chassis members. The LH chassis requires a cut of approximately 25mm x 45mm, with bolt hole positions at 42mm and 38mm. The RH chassis requires a similar cut, with bolt hole positions at 38mm and 42mm.
The "BUMPER CUTOUT CENTRED ON VEHICLE" illustration shows a profile view of the required cut in the vehicle's bumper. The dimensions provided are 20mm for the height and 155mm for the width of the cutout.
Important Notes
Recommended Torque Setting: For M12 Grade 10.9 bolts, the recommended torque setting is 139 Nm. For other torque settings, please refer to the notes on the overleaf (not provided in this document).
Vehicle Limits: Always observe the nose load limits and the vehicle manufacturer's specified trailer or caravan weight limits.
