Opel Astra Tow Bar Installation Guide

Technical Specifications

D-Value Calculation: D = (max kg × max kg) / (max kg + max kg) × 0.00981 ≤ 8.75 kN

Maximum Towing Capacity: 75 kg (s/ ), 1500 kg (Max.)

Product Overview

This document provides installation instructions and component details for the GDW Ref. 1460 tow bar, designed for Opel Astra vehicles manufactured from April 2004 onwards. GDW nv is the manufacturer.

Visual Description of Assembly Diagram: The primary diagram illustrates the tow bar assembly. It shows the main tow bar structure, the ball coupling, and various mounting components. Numbered parts (1-4) and connection points (A, B, C, D) are indicated, showing how the tow bar is attached to the vehicle's chassis using bolts, nuts, washers, and specialized tubes and plates. A magnified view highlights a specific connection detail.

Visual Description of Clearance Diagram: This diagram outlines the necessary clearance zones around the tow bar coupling to ensure compliance with regulations. It specifies maximum angles (e.g., 30°, 45°) and minimum/maximum dimensions for various points and radii (e.g., min. 32mm, max. 100mm, min. 65mm, min. 55mm, min. 75mm, max. R14.5, max. R40). It also indicates a vertical distance range of 350-420 mm. The diagram notes that these clearances must conform to supplement VII, diagram 30 of guideline 94/20/EG.

Installation Instructions

1. Remove the floor covering and side lining from the trunk, and disassemble the bumper.
2. Drill the pre-existing holes on the underside of the chassis (identified by an indentation in the trunk) using a Ø10.5mm drill bit. Enlarge only the top plate of these holes to Ø25mm. Insert the distance tubes (3) and (4) through these Ø25mm openings into the chassis beam. Remove any bitumen coating from the areas where the tow bar components will be mounted. Place the counter plates (1) and (2) onto the mounting tubes and insert the bolts.
3. Position the tow bar with its designated points (A, B, C, and D) against the underside of the chassis, aligning with the provided holes. Attach the appropriate washers and nuts, and tighten all fixings securely according to the specified torque values.
4. Mount the ball coupling together with the safety shackle and tighten all fixings securely according to the specified torque values.

Composition (Parts List)

• 1 x Ball coupling T45M002
• 2 x Bolts M12x65 - DIN931
• 2 x Bolts M12x60 - DIN931
• 4 x Lock nuts M12 - DIN985
• 2 x Mounting tubes T45
• 2 x Mounting shells T45
• 1 x Safety shackle (-s) (800.000)
• 4 x Bolts M10x90 - DIN931
• 4 x Nuts M10 - DIN934
• 4 x Lock washers M10 - DIN128A
• 2 x Tubes Ø25x5.6x55mm (4)
• 2 x Tubes Ø25x5.6x60mm (3)
• 2 x Washers 40x35x12x4mm
• 1 x Mounting piece (2)
• 1 x Mounting piece (1)

Note: All bolts and nuts are quality 8.8.

Torque Specifications

Quality 8.8 Bolts

Quality 10.9 Bolts

Important Notes

• For the maximum permissible towing mass for your vehicle, consult your vehicle dealer or owner's manual.
• Remove any bitumen coating or sound-deadening material from the fastening points.
• When drilling, exercise caution to avoid damaging any brake lines, electrical wiring, or fuel lines.