GDW Tow Bar Installation Guide
For Volkswagen Passat and Skoda Superb
General Information
This document provides installation instructions for GDW tow bars compatible with Volkswagen Passat (from 01/15 onwards) and Skoda Superb (from 09/15 onwards) models.
Manufacturer: GDW nv
Website: www.gdwtowbars.com
Reference Number: 2096
Revision Date: 19.11.2015
General Instructions
Fitting
- Before starting, inspect the tow bar for any transport damage and confirm it is the correct model for your vehicle.
- Read and meticulously follow all instructions provided in this manual.
- Present the tow bar under the vehicle to check alignment and fit before proceeding with permanent installation.
- When drilling holes, ensure no electrical wiring, brake lines, or other critical components are present. Remove any soundproofing or bitumen layers. Treat drilled holes and surrounding metal with an anti-corrosive product.
- If the vehicle is equipped with non-standard bumpers (e.g., special series, sport packages, tuning modifications), consult GDW technical service to ensure compatibility and proper fitment.
- Tow bars delivered pre-assembled for storage purposes must have their parts disassembled before commencing the actual installation.
Guarantee
- To determine your vehicle's maximum towing capacity, consult the Certificate of Conformity (COC) or contact your vehicle dealer. Do not exceed the specified tow bar limits.
- The tow bar requires inspection after the first 1,000 km of use and at least annually thereafter.
- During inspections:
- Check all bolted connections and retighten as necessary.
- Repair any damage to the paint finish.
- Replace any components that have been damaged due to accidents or impacts.
- Grease the internal components of detachable tow bar systems.
Usage
- If the towing ball obstructs the license plate or fog light, it is mandatory to remove the ball when the tow bar is not in use.
Technical Specifications
Torque Settings
The following torque values are recommended for securing bolts, based on their size and grade:
| Bolt Size | Grade 8.8 (Nm) | Grade 10.9 (Nm) | Grade 12.9 (Nm) |
|---|---|---|---|
| M6 | 11.3 | 16.5 | 19.3 |
| M8 | 27.3 | 40.1 | 46.9 |
| M10 | 54.0 | 79.0 | 93.0 |
| M12 | 57.0 | 83.0 | 98.0 |
| M14 | 93.0 | 137.0 | 160.0 |
| M16 | 97.0 | 143.0 | 167.0 |
Diagrams show various torque wrenches and sockets (e.g., 10, 13, 17, 19, TX15, TX25, TX30) used for installation.
Vehicle Compatibility
- Volkswagen Passat (Model year 2015 onwards)
- Volkswagen Passat Variant (Model year 2015 onwards)
- Skoda Superb Combi (Model year 2015 onwards)
- Skoda Superb Berline (Model year 2015 onwards)
Clearance and Weight Limits
Ensure compliance with clearance requirements as specified in Appendix VII, diagram 25 (a,b) of regulation nr. 55.
D Value Calculation: D = (v2 * Σ(m1*m2) / (m1+m2)) * 0.00981. For this tow bar, the D value is 11.55 kN.
S Value Calculation: S = (m1*m2) / (m1+m2). The maximum permissible vertical load (S value) on the ball is 140 kg, and the maximum towing weight is 2400 kg.
Diagrams illustrate the required clearance angles and dimensions around the tow ball, and the calculation formulas for D and S values, relating to vehicle weight.
Parts List
The following parts are supplied with the tow bar kit:
- 1: GDW REF. 2096 (Main tow bar assembly) - x1
- 2: GDW REF. 2 (Tow bar arm/receiver) - x1
- 3: GDW REF. 3 (Tow ball assembly) - x1
- 4: DIN9021-M10-ELVZ (Washer) - x4
- 5: DIN128A-M10 (Spring washer) - x6
- 6: DIN933-M10x40 (Bolt) - x6
- 7: DIN125-A10-140HV-ELVZ (Washer) - x2
- 8: DIN934-M10 (Nut) - x2
- A: GDW REF. 900.008 (Electrical socket bracket) - x2
- B: GDW REF. 900.011 (Spacer/Bracket component) Ø 21.3 x 11.7 - x2
- C: DIN931-M12 x 70 (Bolt) - x2
- D: DIN985-M12 (Lock nut) - x2
- X1: 944.J039 (Specific bracket/part) - x1
- X2: GDW REF. 900.053 (Specific bracket/part) - x1
- PO4: GDW REF. PO4 (Part not explicitly detailed in list but shown in diagrams) - x1
Diagrams on page 7 show visual representations of these parts.
Installation Steps
Follow these steps carefully for the correct installation of the GDW tow bar.
Step 1: Preparation and Access
Page 8: A warning symbol is displayed. The rear of the vehicle (Volkswagen Passat/Skoda Superb) is shown. Access panels in the rear bumper area are indicated.
Open the trunk and locate the access panels on the left and right sides of the rear bumper interior.
Page 8: Close-up views show how to remove the left and right access panels, indicated by arrows suggesting pulling them outwards.
Step 2: Bumper Removal (General)
Page 9: Shows the rear of the vehicle with the trunk open. Arrows indicate the removal of the taillight assemblies.
Remove the taillight assemblies from the vehicle.
Page 9: Shows the removal of the rear bumper. Arrows indicate the direction of removal. A spring and a "Original Skoda part" are shown, suggesting a part that might need to be removed or retained.
Carefully remove the rear bumper. Note any original parts that may need to be retained or removed.
Step 3: Bumper Modification (Volkswagen Passat)
Page 10: Shows the rear of the Volkswagen Passat with the bumper removed. A diagram indicates a cut-out required in the bumper for the tow bar. Dimensions are provided: 140mm width, 80mm height, with a 120mm offset from the center.
For Volkswagen Passat models, a specific cut-out must be made in the rear bumper. The dimensions are approximately 140mm wide, 80mm high, centered 120mm from the vehicle's centerline.
Step 4: Bumper Modification (Skoda Superb)
Page 17 & 21: Shows the rear of the Skoda Superb with the bumper removed. A diagram indicates a cut-out required in the bumper for the tow bar. Dimensions are provided: 100mm width, 60mm height, with a 125mm offset from the center.
For Skoda Superb models, a specific cut-out must be made in the rear bumper. The dimensions are approximately 100mm wide, 60mm high, centered 125mm from the vehicle's centerline.
Step 5: Accessing Mounting Points
Page 9: Shows the vehicle chassis after bumper removal. Mounting points are indicated. Tools like a torque wrench (10) and socket are shown.
Access the designated mounting points on the vehicle's chassis.
Page 11: Shows the underside of the vehicle. Multiple mounting points are indicated with arrows. Tools TX15 and TX25 are shown.
Locate and prepare all chassis mounting points.
Step 6: Installing Tow Bar Brackets
Page 10: Shows the tow bar frame being positioned under the vehicle.
Position the main tow bar frame under the vehicle.
Page 11: Shows the tow bar frame being attached to the chassis using bolts and washers.
Attach the tow bar frame to the vehicle chassis using the provided bolts and washers.
Page 12: Shows the tow bar frame being secured to the chassis with bolts and nuts.
Secure the tow bar frame to the chassis using the specified bolts and nuts.
Page 13: Shows specific brackets (labeled 2 and 3) being attached to the chassis mounting points using bolts (labeled 13).
Attach the specific tow bar brackets (e.g., parts 2 and 3) to the chassis mounting points using the appropriate bolts.
Page 14: Shows the tow bar frame (labeled 17) being attached to the chassis with bolts (labeled 9, 5, 4, 6).
Attach the main tow bar frame using the specified bolts and washers.
Page 15: Shows the tow bar frame being secured to the chassis with bolts (labeled 17).
Continue securing the tow bar frame to the chassis.
Page 16: Shows the tow bar mechanism being attached to the main frame using bolts (labeled 17).
Attach the tow ball mechanism to the main tow bar frame.
Page 17: Shows the electrical socket bracket (A) and spacer/bracket component (B) being attached to the tow bar frame using bolts (C) and lock nuts (D).
Mount the electrical socket bracket (A) and associated components (B, C, D) onto the tow bar frame.
Step 7: Final Assembly and Reinstallation
Page 18: Shows the tow bar assembly fully mounted. Arrows indicate the reinstallation of the bumper.
With the tow bar assembly securely mounted, prepare for bumper reinstallation.
Page 18: Close-up views show the attachment of the tow bar to the vehicle's side mounting points using bolts (labeled 17).
Secure the tow bar to the vehicle's side mounting points.
Page 19: Shows the specific parts for the tow ball assembly (A, B, C, D) and the electrical socket bracket.
The diagram illustrates the final assembly of the tow ball and electrical socket components.
Page 20: Shows the tow ball mechanism and various optional accessories.
The tow ball mechanism and available options are displayed.
Page 22: Shows the rear bumper being reinstalled onto the vehicle, aligning with the tow bar assembly.
Reinstall the rear bumper, ensuring it aligns correctly with the installed tow bar.
Step 8: Final Checks
Ensure all bolts are tightened to the specified torque values. Verify the proper functioning of the tow bar and electrical connections (if applicable).
Vehicle Specific Notes
Volkswagen Passat (from 01/15): Requires a bumper cut-out of approximately 140mm width x 80mm height, offset 120mm from the center.
Skoda Superb (from 09/15): Requires a bumper cut-out of approximately 100mm width x 60mm height, offset 125mm from the center.
Regulatory Information
Clearance requirements must adhere to Appendix VII, diagram 25 (a,b) of regulation nr. 55.
D Value: 11.55 kN
S Value (Max Vertical Load): 140 kg
Max Towing Weight: 2400 kg
Diagrams on page 21 illustrate clearance angles and dimensions, and the relationship between vehicle weight and towing capacity.
