Hayman Reese Installation Instructions

Towbar Installation Instructions (Part No. 02022RW)

Installation Time: Approx 45 Minutes

Towbar Capacity: Max Towing Braked 2700kg, Max Static Ball Load 270kg

An image shows the rear of a silver Ford Territory SUV.

Key Information and Warnings

• WARNING: Ford Motor Company recommends the use of a load leveling kit to achieve maximum towing capacity.
• Do not drill, cut, weld, or otherwise modify the towbar.
• When using electric welding on a vehicle, always check for electronic engine or instrument management equipment to avoid damaging onboard computers. Consult the vehicle manufacturer if unsure.
• Ensure all hardware items are included as per the assembly diagram.
• Read and understand all instructions completely before fitting.
• Be aware of potential conflicts with vehicle design changes or other accessories.
• Before drilling, ensure the area is clear of fuel, electrical components, and other obstructions.
• Remove all burrs and swarf from drilled holes and coat with rust preventative paint.
• Use only high-tensile fasteners of the same rating and quality as supplied. Contact an authorized Hayman Reese dealer for replacements.
• Fasten all hardware to the specified torque and check 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 complies with Australian standards AS 4177.2.
• PLEASE NOTE: Remove the tow ball mount (lug or tbm) when not towing to ensure clear visibility of the number plate and maximize departure angle.

Towbar Maintenance and Care

• Routinely inspect and check bolt torque for correct tension. Replace any worn or defective parts.
• Remove Tow Ball Mounts (TBMs) when not in use for extended periods.
• For safety, remove the tongue, Pull Pin, and R-clip when not towing and store them in a safe, clean, dry place.
• Regularly check Hitch Pull Pins and spring "R" clips for proper installation and replace if worn or defective.

Assembly Diagram and Parts List

Diagram illustrating the various components included in the towbar kit, with a corresponding parts list detailing quantity, description, and item number. Key items include the towbar itself, mounting arms, hardware, a wiring loom, plastic inserts, and a bumper trim pinch weld.

Installation Steps

Step 1: Preparation

• Ensure all hardware items are included.

Step 2: Tail Light Removal

• Remove tail lights by unscrewing 3 x 6-torx head screws (or Phillips head screws) per tail light.
• Unplug the tail light connection for each light.
• Remove 2 x 10mm nuts located behind the lights.
• (For FORD TERRITORY SZ 2011 On models, refer to specific diagrams for tail light removal.)
• Diagrams show the removal of the vehicle's tail lights, including details on screws, clips, and connections.

Step 3: Bumper Bar Removal

• Remove 2 plastic trim plugs and 2 screws on the underside of each wheel arch.
• If mudguards are fitted, screws may replace trim buttons.
• Remove 7 plastic trim buttons on the underside of the bumper bar.
• If reverse sensors are fitted, disconnect them.
• Flex the bumper bar out from the sides and pull it rearward.
• Remove 2 plastic tabs inside the bumper bar using a sharp knife.

Step 4: Rear Panel Modification

• Cut the rear panel as per diagram using tin snips, then fold the section up and flat. (See Figures 1 & 2).
• Diagrams show the driver's and passenger sides of the vehicle, indicating where to cut and fold the bumper (50x25mm) and highlighting the location of captive bushes for bolt installation.

Step 5: Towbar Mounting

• Lift the towbar into position, aligning holes in the side plates with holes in the sub-frame.
• Support the towbar with suitable jack stands or a jack.
• Drive the supplied taptite bolts into the captive bushes in six places (three on each side, two at each end of the sub-frame and one underneath each side) using a suitable rattle gun.
• Loosen the taptite bolts slightly to allow for bar manipulation into the correct position.
• From under the crosstube, fit two vertical taptites with loose plates to suit the gap between the impact beam and crosstube.
• Ensure all six mounting points in the sub-frame are accounted for.

Step 6: Final Tightening and Fitment

• Tighten all bolts on the impact beam to the specified torque.
• Fit the loose mounting arms to the towbar. Ensure the longer arm is on the passenger side and the shorter arm is on the driver's side, with spacer tubes fitted between the bar and the arms.
• Tighten bolts semi-tight, ensuring the arms are square and straight to the sub-frame.
• Using the holes in the loose arms as a guide, drill 13mm holes on the underside of the chassis rails: three places on the passenger side and two places on the driver's side.
• Feed the support chassis brackets through the chassis rail holes and align them with the drilled holes.
• Fit bolts and washers as per the diagram.
• Tighten all bolts to the torque listing, then cut excess wire from nuts and bolts.
• Fit plastic inserts into access holes as per the fitting diagram.
• Cut the bumper as per Figure 3 and fit the pinch weld.
• Remove and discard screws in 2 places, and trim off plastic tabs (see Figure 3).
• Refit the bumper by following Step 3 (removal) in reverse, then Step 2 (tail light reinstallation).

Step 7: Bumper Cut Template Instructions (Fig 3)

• NOTE: Please ensure the template is to scale before cutting the bumper.
• Establish the centre line of the bumper bar through the vertical plane of the hole as shown.
• Diagram labeled 'FIG 3 BUMPER CUT' shows the rear bumper with specific cut lines and measurements. It details cutting two tabs, placing a template (A02022R-10), establishing a centre line, and measuring from the bumper's base.
• Cut along the outside profile with an air-operated hacksaw or similar saw.
• For TX 04/2004 - SY 2010 models: Position the bottom of the cut-out template 40mm from the base of the bumper on the inside of the bumper bar.
• For SZ MODELS 2011-On: Position the bottom of the cut-out template 45mm from the base of the bumper on the inside of the bumper bar.
• Place the centre line of the cut-out template in alignment with the centre line of the bumper bar.
• Drill through 20mm in each corner to achieve a 10mm radius. The outside of the drill bit should be concentric with the corner profile.
• PLEASE NOTE: You must remove the lug unless you are actually towing if it obscures your number plate. Failure to do so may result in a fine.

Recommended Assembly Torque Listing

FOR TOWING PURPOSES ONLY: For towing capacity details, please refer to the vehicle owner's manual or the manufacturer. Overloading can void your warranties.

Wiring Loom Installation Instructions (Part No. 100001-WL)

Wiring Loom Installation Time: Approx 30 Minutes

Tail Harness Required Part No: 04816

Vehicle Compatibility: FORD BA/BF, SX/SY/SYII & SZ TERRITORY

Installation Steps

1. Remove the rear boot trim by unscrewing the cargo strap mounts (1) and remove panel (2).
2. Remove seatbelt bolts.
3. Remove plastic covers (x3) to reveal and unscrew mounting screws.
4. Unscrew tie down mounts (x2).
5. Remove the RHS rear door seal.
6. Remove the RHS rear upper trim.
7. Dislodge the lower trim, disconnect the 12V auxiliary connector, then remove the panel completely.
8. Illustrations demonstrate the removal of rear boot trim, cargo strap mounts, and panels. Further images show the process of removing seatbelt bolts, plastic covers, tie-down mounts, rear door seals, and upper trim. A close-up shows disconnecting the 12V auxiliary connector.
9. Locate the vehicle's trailer breakout connector.
10. Connect the Trailer Patch harness (P/No: 100001-WL) to the break-out connector.
11. On the RHS rear, below the tail light, remove the grommet and feed the tail harness (Part No. 04816) through the hole until it comes through the inner cavity.
12. Connect the trailer patch harness to the tail harness.
13. Secure the trailer socket onto the towbar mounting plate using M4 fasteners.
14. Test the trailer harness using a light board or multimeter.
15. Secure all harnesses using cable ties.
16. Refit all removed parts and secure all fasteners, ensuring there are no squeaks or rattles.
17. Place these instructions in the glove box after fitment.