GDW Tow Bar Mounting Instruction

Important Advice

General Mounting & Usage Guidelines

• Before starting, inspect the tow bar for any transport damage and verify it is the correct reference for your vehicle.
• Read and follow all instructions in this mounting manual precisely.
• Present the tow bar under the vehicle before drilling or making any modifications.
• If drilling is required, ensure no electrical wires, brake lines, or other components are damaged. Remove any soundproofing or bitumen layers. Treat drilled holes and chassis parts with an anti-corrosive product.
• If the vehicle has non-standard bumpers (e.g., special series, sport versions, tuning parts), consult GDW technical service before proceeding to ensure compatibility.
• The tow bar supplied is often assembled for storage; disassemble parts as needed for installation.
• To determine your vehicle's correct towing weight, refer to the Certificate of Conformity (COC) or contact your dealer. Do not exceed the tow bar's specifications.
• The tow bar must be checked after the first 1,000 km of use and at least once a year. Check and retighten all bolts, repair any paint damage, replace damaged components, and lubricate parts of detachable systems.
• If the tow ball obstructs the license plate or fog light, it must be removed when not in use.

Technical Specifications

D-Value: 9.65 kN

S-Value (Vertical Load): 100 kg

Maximum Trailer Weight: 1850 kg

Required Tools: TX20, TX25, Wrenches (7, 13, 17, 19)

Clearance Requirements: Must comply with Regulation nr. 55, Appendix VII, diagrams 25 (a,b).

Parts List

The following parts are typically included:

• 1: Tow Bar Main Assembly (GDW REF. 2178)
• 2: Left Tow Bar Bracket (GDW REF. 2)
• 3: Right Tow Bar Bracket (GDW REF. 3)
• 4: Tow Bar Frame Component (GDW REF. 4)
• 5: Tow Ball Mount (GDW REF. 5)
• 6: DIN933-M10x40 Bolts (x6)
• 7: DIN125-A10 Washers (x6)
• 8: DIN128A-M10 Lock Washers (x6)
• 9: DIN934-M10 Nuts (x6)
• 10: DIN9021-M12 Washers (x4)
• 11: DIN128A-M12 Lock Washers (x4)
• 12: DIN933-M12x40 Bolts (x4)
• 13: DIN125-A12 Washers (x2)
• 14: DIN934-M12 Nuts (x2)
• Other Components: 944.L035, GDW REF. P33, GDW REF. 900.008, GDW REF. 908.070, M10x20 (NYLON), Ø24x13x2.5 (NYLON), GDW REF. 900.011, Ø21.3x11.7, DIN931-M12x70, GDW REF. 900.053.

Installation Steps

Follow these steps for installation. Refer to the part numbers indicated in the diagrams.

Step 1-2: Access the rear of the vehicle. Open the tailgate and remove interior trim panels on the left and right sides of the rear bumper area to gain access to mounting points.

Step 3: Carefully remove the vehicle's rear bumper. This usually involves releasing clips and fasteners.

Step 4: Remove the original bumper reinforcement bar, typically held by bolts.

Step 5: Remove the main rear undertray or splash guard, usually secured with screws or clips.

Step 6: Remove any side undertray or wheel arch liner sections that may obstruct access to the chassis mounting points.

Step 7: Prepare the vehicle chassis for mounting. This may involve cleaning or removing any existing protective coatings at the mounting locations.

Step 8: Attach the left tow bar bracket (2) to the vehicle's chassis using specified bolts (e.g., 12) and nuts (9).

Step 9: Attach the right tow bar bracket (3) to the vehicle's chassis using specified bolts (e.g., 12) and nuts (9).

Step 10: Position the main tow bar assembly (1) and align it with the brackets (2, 3). Secure it using bolts (e.g., 12) and nuts (14).

Step 11: Loosely install the primary tow bar frame components (e.g., 1, 2, 3) to the vehicle's chassis mounting points using bolts (e.g., 12) and nuts (e.g., 14). Do not fully tighten yet.

Step 12: Continue attaching the tow bar frame to the chassis, ensuring all mounting points are aligned. Use bolts (e.g., 12) and nuts (e.g., 14).

Step 13: Secure the tow bar frame to the chassis. Ensure all bolts are correctly seated.

Step 14: Install any additional chassis mounting brackets (e.g., 10, 11, 14) as required, using the appropriate hardware.

Step 15: Install the tow bar mounting brackets (e.g., 4) onto the main tow bar assembly, using bolts (e.g., 6, 7, 8, 9).

Step 16: Install the tow bar mounting brackets (e.g., 4) onto the main tow bar assembly, using bolts (e.g., 6, 7, 8, 9). Tighten to specified torque (e.g., 27.3 Nm).

Step 17: Re-install the vehicle's rear bumper. Ensure it fits correctly over the installed tow bar components.

Step 18: Re-install any removed trim panels or undertrays.

Step 19: Install the tow bar hitch receiver or main tow bar structure, aligning it with the chassis mounts.

Step 20: Secure the tow bar structure to the chassis using bolts (e.g., 6) and nuts (e.g., 9), washers (e.g., 7, 8). Tighten to specified torque (e.g., 54.0 Nm).

Step 21: Re-install the undertray or splash guard (e.g., 18), ensuring it fits around the tow bar components.

Step 22: Re-install any remaining undertray components or trim panels.

Step 23: Attach the tow ball (e.g., A) to the tow bar hitch receiver. Secure with bolts (e.g., A, D) and nuts (e.g., B, E), and washers (e.g., C). Tighten to specified torque (e.g., 3.0 Nm).

Step 24: Attach the tow ball assembly (e.g., A) to the tow bar. Secure with bolts (e.g., C) and nuts (e.g., D), and washers (e.g., B). Tighten to specified torque (e.g., 93.0 Nm).

Step 25: Re-position the rear bumper, ensuring it aligns correctly with the tow bar installation.

Step 26: Re-attach the rear bumper, securing it with its original fasteners.

Step 27: Finalize the tow ball attachment. Secure the tow ball (A) using bolts (B) and nuts (C), and washers (S). Tighten to specified torque (e.g., 93.0 Nm).