GDW Tow Bar for Ford Mondeo 5D (2007-2014)
GDW Reference: 1653
General Information
This document provides comprehensive details and installation instructions for the GDW tow bar, reference number 1653, designed for the Ford Mondeo 5D model manufactured from June 2007 onwards.
EEC Approval Number: e6*94/20*0680*00
Technical Specifications
The following specifications are provided for the tow bar system:
| Specification | Value |
|---|---|
| D-Value | Calculated as: max kg X max kg X 0.00981 ≤ 11.60 KN |
| S-Value (Vertical Load) | Max. 80 kg |
| Maximum Vehicle Towing Capacity | Max. 2300 kg |
Composition and Parts List
The tow bar kit includes the following components:
| Item | Description | GDW Ref. | Quantity |
|---|---|---|---|
| 1 | Nut (DIN985 - M12 8.8) | T45J000 | 4x |
| 2 | Bolt (DIN931 - M12x70 - 8.8) | 800.008 | 4x |
| 3 | Bolt (DIN933 - M10x35 - 8.8) | 800.011 | 6x |
| 4 | Washer (DIN128-A10-FSt) | 800.053 | 6x |
| 5 | Washers (Ø40x35x12x4) | 905003 | 6x |
| 6 | Tow Ball Assembly | P04 | 1x |
| 7 | Tow Bar Main Unit | 1653 | 1x |
Bolt Torque Specifications
Torque values for various bolt grades and sizes are provided for secure installation:
| Bolt Type/Grade | M6 | M8 | M10 | M12 | M14 | M16 |
|---|---|---|---|---|---|---|
| Quality 8.8 (Nm / kgm) | 10.8 / 1.1 | 25.5 / 2.6 | 52.0 / 5.3 | 88.3 / 9.0 | 137 / 14.0 | 211 / 21.5 |
| Quality 10.9 (Nm / kgm) | 13.7 / 1.4 | 35.3 / 3.6 | 70.6 / 7.2 | 122.6 / 12.5 | 194 / 19.8 | 299.2 / 30.5 |
| Quality 12.9 (Nm / kgm) | 18 / 1.8 | 43 / 4.4 | 87 / 8.9 | 150 / 15.3 | 240 / 24.5 | 370 / 37.7 |
Installation Instructions
Follow these steps for fitting the tow bar to your Ford Mondeo 5D:
General Steps:
- Disassemble the bumper. Lower the exhaust system and loosen the heat shield. Permanently remove the metal buffer beam.
- Insert the tow bar into the chassis beams through the freed openings. Ensure points (A) align with the provided holes in the chassis beam sides. Insert bolts and tighten securely according to the specified torque values.
- Reassemble the heat shield, reattach the exhaust system, and refit the bumper onto the vehicle.
- Assemble the tow ball (*) along with the socket plate holder and the safety ring. Insert bolts and tighten securely according to the specified torque values.
Bumper Disassembly:
To remove the bumper:
- Remove 2 screws at the trunk entrance.
- Remove 2 screws located under the bumper.
- Remove 2x3 screws from the splashguard or wheel arch liner.
- Unclip the sides of the bumper. For the side directly under the rear light, unclip and slide the bumper backward.
Important Advice and Usage Notes
Fitting Precautions:
- Before starting the installation, inspect the tow bar for any transport damage and verify it is the correct reference for your vehicle.
- Read and follow the fitting instructions very precisely.
- Present the tow bar under the car first to check if all mounting points align correctly.
- If holes need to be drilled, carefully check that no existing wires (electrical, brake, or fuel lines) can be damaged. Remove any soundproofing or bitumen coatings from the mounting area. Treat drilled holes and chassis parts with an anti-corrosive product.
- If the vehicle is equipped with non-standard bumpers (e.g., special series, sport versions, tuning parts), it is imperative to consult GDW technical service before proceeding with the installation.
Guarantee and Maintenance:
- Do not exceed the indicated towing weight, "D", and "S" values for your vehicle.
- The tow bar must be checked after the first 1,000 km of use and at least annually thereafter.
- Check all bolt connections and retighten if necessary.
- Repair any damage to the paint finish.
- Replace any components that have been damaged due to an accident or collision.
- For detachable tow bars, ensure the internal parts are kept well greased.
Usage:
- If the tow ball covers the number plate or the fog light when the trailer is not attached, it must always be removed.
- For the maximum permissible towing mass of your vehicle, consult your vehicle dealer or owner's manual.
Clearance Specifications
The following diagrams illustrate the required clearance dimensions as per guideline 94/20/EG, Annex VII, illustration 30:
Diagram 1 (Side View Clearance):
This diagram details side clearance requirements for the tow bar mounting. Key dimensions include:
- Maximum angle clearance: 30°, 45°
- Minimum clearances measured from line A-A: 32, 55, 65, 100, 140 (units assumed to be millimeters).
- Vertical clearance range: 350 to 420 (units assumed to be millimeters).
- Note: "The clearance specified in appendix VII, diagram 30 of guideline 94/20/EG must be guaranteed."
- Note: "For permissible total weight of the vehicle."
Diagram 2 (Ball/Mounting Clearance):
This diagram shows clearance requirements related to the tow ball and its mounting points. Key dimensions include:
- Maximum angle clearance: 30°
- Minimum clearance from line A: 75 (units assumed to be millimeters).
- Radii specifications: Max. R14.5, Max. R40.
- Note: "For permissible total weight of the vehicle."
