Hayman Reese Towbar Installation Instructions

Important Information

ECU Part Number: 04836

Tail Harness Required: Length 1200mm, Part Number 04937 (for vehicles equipped with Rear Park Assist)

RPA Disable Information: Via Wiring Loom

Electric Brake Location: Blue Wire Near Grommet

Warnings

• Do not drill, cut, weld, or otherwise modify the towbar.
• When using electric welding on a motor vehicle, verify it is not equipped with electronic engine or instrument management equipment, as this could destroy on-board computers. Consult the vehicle manufacturer if unsure.
• Using the Tow Ball Mount (TBM) in an inverted position may cause contact with the rear tailgate when lowered, potentially leading to damage.

General Installation Guidelines

• Ensure all hardware items are included before starting; refer to the assembly diagram.
• Read and fully understand these instructions before attempting installation.
• Be aware of any vehicle design changes or other accessories that might conflict with this product's installation.
• Before drilling, ensure the area is clear of fuel, electrical, and other components.
• After drilling, remove all burrs and swarf from body panels and apply a suitable rust-preventative paint.
• The high-tensile fasteners supplied were used to achieve the specified rating. If replacements are needed, ensure they are of the same rating and quality. Contact an authorised Hayman Reese dealer for further information.
• Ensure all hardware is fastened to the specified torque values and check fasteners regularly.
• The towbar load rating sticker must be conspicuously located on the inside rear end of the driver's door.
• Hayman Reese recommends checking your tow ball for compliance with Australian Standard AS 4177.2.
• It is advised to remove your Tow Ball Mount (TBM) when not towing to ensure a clear view of the vehicle's registration plate (if obscured) and to provide maximum departure angle.

Towbar Maintenance and Care

Hayman Reese recommends that bolt torques are routinely and regularly inspected and checked for correct tension. Replace any worn or defective parts.

It is recommended to remove Tow Ball Mounts (TBM's, tongues or lugs) when not being used for any considerable length of time.

To avoid injury, when not towing, it is suggested that the tongue, Pull Pin, and R-clip are removed and stored in a safe, clean, and dry place, away from excessive moisture. Hitch Pull Pins and spring "R" clips should be regularly checked for proper installation. Replace any worn or defective parts.

Recommended Assembly Torque Listing

Parts List

Installation Steps

1. Step 1: Remove Wheel Arch Screws

   Inside the wheel arch, remove 2 screws. Repeat this process for the other side.

   [Diagram Description: Shows the rear wheel arch area of the vehicle with arrows indicating the location of two screws to be removed.]

2. Step 2: Access Bumper Screws

   Open the rear door to expose 2 screws securing the bumper. Remove these screws.

   [Diagram Description: Shows the rear of the vehicle with the tailgate open. Arrows point to two screws located on the bumper that need to be removed.]

3. Step 3: Remove Bumper Scrivets

   Remove the 5 scrivets located under and along the length of the bumper.

   [Diagram Description: Shows the underside of the vehicle's rear bumper with arrows pointing to five scrivets that need to be removed.]

4. Step 4: Remove Impact Beam Bolts

   On the Right Hand (RH) side, remove the 2 bolts securing the impact beam to the chassis rail. Repeat this for the Left Hand (LH) side.

   [Diagram Description: Shows the chassis rail area of the vehicle with arrows indicating the two bolts that secure the impact beam.]

5. Step 5: Remove Bumper Assembly

   Carefully remove the bumper by peeling it away from the sides. Ensure to disconnect any main electrical plugs located under the bumper on the LH side. Note: The impact beam will come away with the bumper.

   [Diagram Description: Illustrates the process of carefully pulling the bumper away from the vehicle's sides.]

6. Step 6: Loosely Secure Side Arm Assemblies

   Loosely secure the RH Side arm assembly to the side of the chassis using one M10 x 130 bolt, two washers, one crush tube, one spacer, and one M10 nut. Ensure the crush tube does not fall into the chassis rail. The spacer should fit between the side arm and the chassis rail. Loosely secure the bottom of the side arm with two M10 bolts, each with one washer. Repeat this process for the other side.

   [Diagram Description: Shows a side arm assembly being loosely attached to the vehicle's chassis rail using bolts, washers, a crush tube, and a spacer. A detail highlights the 130mm bolt and spacer placement.]

7. Step 7: Attach Crosstube and Torque Fasteners

   Lift the crosstube to the side arm assemblies and secure it using six M10 x 40 x 1.25P bolts, each with two washers and one M10 nut (three bolts per side). Position the towbar and torque all fasteners according to the following specifications:

   • M10 (GR8.8): 44 Nm
   • M10 (GR 10.9): 68 Nm

   [Diagram Description: Shows the towbar crosstube being attached to the side arm assemblies. Arrows indicate bolt locations. Torque values are noted.]

8. Step 8: Fit Bumper Tabs

   For LDV Standard models: With the bend facing rearwards of the vehicle, loosely secure the two bumper tabs to the rear of the crosstube using one tek screw per bumper tab, as depicted.

   For LDV Executive models: With the bend facing forwards of the vehicle, loosely secure the two bumper tabs to the front of the crosstube using one tek screw per bumper tab.

   [Diagram Description: Illustrates the fitment of bumper tabs to the crosstube, showing the LDV Standard configuration with the bend facing rearwards.]

9. Step 9: Disconnect Wiring from Impact Beam

   On the inside of the removed bumper, disconnect the wiring harness and connectors from the impact beam. Discard the impact beam.

10. Step 10: Bumper Cut (LDV Standard)

    Locate the centre of the bumper. Mark and cut out a 90mm wide x 50mm rectangle on the bottom of the bumper. On the rear surface of the bumper, cut an 80mm wide x 65mm high rectangle measured from the bottom of the bumper.

    [Diagram Description: Shows the rear of the LDV Standard bumper with cut-out dimensions indicated: a 90mm x 50mm rectangle on the bottom front, and an 80mm x 65mm rectangle on the rear surface, measured from the bottom.]

11. Step 11: Bumper Cut (Executive Model)

    Locate the centre of the bumper. Mark out a 90mm width from the bottom edge, measuring 190mm length running along the outside profile of the bumper. The cut should stop just below the style line.

    [Diagram Description: Shows the side profile of the Executive model bumper with cut-out dimensions indicated: a 90mm width from the bottom edge, extending 190mm along the profile.]

12. Step 12: Drill Holes for Plug Bracket

    At an appropriate position on the bumper, mark out and drill two 5mm holes, 69mm apart, on the bumper skin to support the plug bracket.

    [Diagram Description: Shows the vehicle bumper with two marked points for drilling 5mm holes, 69mm apart, to mount the plug bracket.]

13. Step 13: Refit Bumper and Secure Harnesses

    Refit the bumper to the vehicle following steps 5 to 1 in reverse. Ensure all loose wiring and connectors, removed from the impact beam, are secured to the crosstube using cable ties (not provided).

14. Step 14: Secure Bumper Tabs

    Position and secure the bumper tabs to the crosstube.

15. Step 15: Disconnect Battery Terminal

    Disconnect the vehicle's negative battery terminal.

16. Step 16: Access Rear Trim Components

    Push rear seats forward (1). Remove Lower boot trim (2). Remove 2 screws (3). Remove the Plastic Ventilation Panel on the RHS lower trim (4).

    [Diagram Description: Shows the rear interior of the vehicle with numbered callouts indicating the rear seats, boot trim, screws, and ventilation panel to be removed or adjusted.]

17. Step 17: Remove Rear Lower Trim and Disconnect Light

    Undo the 2 seatbelt Bolts (1). Dislodge LHS rear lower trim (2) and upper trim (3). Disconnect the boot light connector (4). Dislodge the RHS rear lower trim (5).

    [Diagram Description: Shows the rear interior trim panels being removed, with numbered callouts for seatbelt bolts, LHS/RHS lower and upper trims, and the boot light connector.]

18. Step 18: Route Connectors and ECU

    Route the 12-way (1) connector to the upper RHS rear trim. Route the grommet (2) to the lower RHS trim. Route the 1-way terminal with Yellow/Black wire (3) to the LHS tail light.

    [Diagram Description: Illustrates the routing of electrical connectors and wires within the rear interior of the vehicle.]

19. Step 19: Mount ECU

    Mount the ECU (P/N: 04836) (1) behind the upper RHS rear trim using the provided double-sided tape. Ensure the ECU is mounted with the connector pointing downwards.

    [Diagram Description: Shows the ECU being mounted behind the rear trim panel, with the connector oriented downwards.]

20. Step 20: Connect Ground Terminal and Patch Harness

    Mount the M6 ring terminal (1) to the vehicle Ground Stud (2) located behind the lower RHS rear trim. Patch in the 6-way connector (3) using the provided T-patch (4).

    [Diagram Description: Shows the M6 ring terminal being connected to the ground stud and the 6-way connector being patched in using a T-connector.]

21. Step 21: Identify and Connect 10-way Female Connector

    Identify the 10-way Female Connector (1) located behind the lower RHS rear trim. Scotch-lock the 1-Way Terminal with Black/White wire (2) to the Blue wire on Pin G of the 10-way Female Connector (1).

    [Diagram Description: Close-up view of the 10-way female connector and the wire connection being made using a Scotch-lock terminal.]

22. Step 22: Dislodge LHS Tail Light and Route Wires

    Dislodge the LHS tail light (1). Locate the Yellow wire (2) behind the vehicle grommet (3). Scotch-lock the 1-way Terminal with Yellow/Black wire (4) to the Yellow Wire (2).

    [Diagram Description: Shows the LHS tail light area, the location of the yellow wire behind a grommet, and the connection being made with a Scotch-lock terminal.]

23. Step 23: Route Harness Terminals and Grommet

    Route the 7 bare terminals (1) and 1-way White connector out of the 25mm hole (2) on the lower rear RHS of the vehicle. Seat the Grommet (3) onto the 25mm hole (2). Continue routing the harness down and under toward the vehicle towbar.

    [Diagram Description: Shows the rear RHS of the vehicle bumper area, illustrating the routing of harness terminals and the installation of a grommet into a 25mm hole.]

24. Step 24: Connect 7 Bare Terminals to 8-way Connector

    House the 7 bare terminals into the provided 8-way blue Connector as per the following table:

    Terminal	Colour	Function
    1	Yellow	Left Indicator
    2	Black	Reverse
    3	White	Ground
    4	Green	Right Indicator
    5	Blue	Service Brake
    6	Red	Brake
    7	Brown	Tail
    8	-	-

    Ensure the connector locking tab is secured after installation.

    [Diagram Description: Shows the front view of the 8-way female connector with terminals numbered 1 through 8.]

25. Step 25: Connect RPA Disable Cable

    Locate the 10-way Female connector (1) between the vehicle and rear fascia. Patch the RPA disable cable (2) onto the 10-way female connector (1).

    [Diagram Description: Shows the 10-way female connector and the RPA disable cable being connected.]

26. Step 26: Route Power Harness

    Starting from the positive battery terminal, route the power harness (1) (P/N: 04825) down through the engine bay and along the underbody, toward the rear of the vehicle. Follow existing wiring where possible and use cable ties (not supplied) to secure it in place.

    [Diagram Description: Illustrates the routing of the power harness from the engine bay, under the vehicle, towards the rear.]

27. Step 27: Connect Trailer Connector

    At the rear of the vehicle, connect the 1-way trailer connector to the mating 1-way connector on the power harness.

28. Step 28: Mount Trailer Socket

    Mount the trailer socket (1) from the tail harness (P/N: 04937) using M4 fasteners (not supplied). Route the tail harness (2) up and across toward the RHS.

    [Diagram Description: Shows the rear of the vehicle with the trailer socket being mounted and the tail harness being routed.]

29. Step 29: Connect Blue Connectors and Crimp RPA Cable

    Connect blue connectors together (1). Crimp the RPA disable cable (2) to the Tail connector as per the table, ensuring wires are properly insulated after crimping.

    RPA Disable wire colour	Tail harness wire colour
    Black	Grey
    Black / White	Grey / Black

30. Step 30: Test Harness and Secure Components

    Test the Trailer Harness function using a light board or multi-meter. Secure all harnesses using cable ties (not supplied).

31. Step 31: Re-fit Parts and Final Check

    Re-fit removed parts and secure all fasteners, ensuring there are no squeaks or rattles.

32. Step 32: Store Instructions

    Place the instructions in the glove box after fitment.

Smart Pin Fitting Instructions

Product: Smart Pin (55070BL)

These fitting instructions are supplied to ensure understanding of how the SMART PIN should be fitted and used correctly.

Once installed, it is recommended that ALL instructions are kept and placed in the vehicle glove box.

Note: Routine maintenance and inspection of the towbar & SMART PIN is required. Regularly inspect for wear and check the tightness of the SMART PIN NUT. Follow instructions below to retighten the nut when necessary.

Warning: Do not tow with your vehicle if the R CLIP or the SMART PIN NUT is loose or missing. Replacement parts are available from your Hayman Reese Distributor.

Step 1: Install Trailer Ball Mount (TBM)

Insert Trailer Ball Mount (TBM) into towbar HITCHBOX, aligning the hole in the TBM SHANK with the hole in the HITCHBOX.

[Diagram Description: Shows a Trailer Ball Mount (TBM) being inserted into a towbar hitchbox, aligning the mounting holes.]

Step 2: Insert Smart Pin

Insert the SMART PIN through the hole in the HITCHBOX and the hole in the TBM SHANK. Ensure the LOCATORS are inserted into the NOTCHES in the HITCHBOX.

[Diagram Description: Shows the Smart Pin being inserted through the aligned holes of the hitchbox and TBM shank, with locators engaging in notches.]

Step 3: Screw on Smart Pin Nut

Screw the SMART PIN NUT onto the SMART PIN. Tighten the SMART PIN NUT until finger tight, ensuring the TBM is restrained from movement.

Step 4: Tighten Smart Pin Nut

Tighten the SMART PIN NUT by turning the nut a further 1/8th of a turn in the clockwise direction using a 24mm spanner.

[Diagram Description: Shows a 24mm spanner being used to tighten the Smart Pin Nut an additional 1/8th turn clockwise.]

Step 5: Install Smart Pin R Clip

Install the SMART PIN R CLIP through the hole on the SMART PIN.

[Diagram Description: Shows the Smart Pin assembly with the R-Clip being inserted through the designated hole on the Smart Pin.]