Tow-Trust Towbars - TP3 Towbar System
Model: TP3
Compatibility: Citroen Relay, Fiat Ducato, Peugeot Boxer Vans (2006 onwards)
Issue: 9
Important: Please read General Notes overleaf before fitting.
Parts List
The following parts are included in the TP3 towbar kit:
| Item | Qty | Description | Item | Qty | Description |
|---|---|---|---|---|---|
| A | 1 | Crossmember | H | 2 | M16 x 60 Bolts & Nyloc Nuts |
| B | 1 | L/H Side Arm | J | 2 | M12 x 130 Bolts & Nyloc Nuts |
| C | 1 | R/H Side Arm | K | 1 | M12 x 70 Bolts & S/P Washers |
| D | 1 | L/H Chassis Bracket | L | 9 | M12 x 40 Bolts, 6 Nyloc Nuts & 3 S/P Washers |
| E | 1 | R/H Chassis Bracket | M | 6 | M10 x 35 x 1.25 Bolts, 2 Nyloc Nuts (1.25) & 6 S/P Washers |
| F | 2 | Captive Clamp Plates | M1 | 4 | M8 x 35 Bolts, S/P Washers & HD Flat Washers |
| G | 1 | Coupling Spacer | N | 2 | M6 Nuts, S/P Washers & Flat Washers |
| P | 2 | 12 x 40 Flat Washers | |||
| R | 8 | 10 x 30 Flat Washers | |||
| S | 16 | 12 x 25 Flat Washers | |||
| T | 2 | 19 x 92 Spacer Tubes (MAXI ONLY) | |||
| V | 1 | 40 x 25 Spacer Tube |
General Installation Instructions
Follow these steps carefully for installation:
- Remove the rear bumper. Open rear doors to reveal Torx head screws (size T30). Remove four fixings along the top edge and four fixings along the bottom edge. Disconnect reversing sensors on the left-hand side (if fitted).
- Cut a section centrally from the lower edge of the bumper. This allows the centre of the towbar to pass through the bumper. Refer to the diagram for precise cutting.
- Remove the bumper beam. The original bumper beam is not refitted with the towbar.
- Using item M with item R (or Item M1) loosely bolt item A (Crossmember) to the existing top two captive holes on each side of the chassis. Also, use item M with item R and provided nuts to attach to the bottom hole on each side. Note: On some models, only two fixings are present on each side; the third fixing will require marking and drilling, being careful not to damage the thread behind.
- Using item J with item P and item S, loosely bolt item B (L/H Side Arm) and item C (R/H Side Arm) to the inside face of each chassis member through the existing holes.
- Using item L with item S, loosely bolt item B and item C to item A (Crossmember).
- Remove the existing square rubber bungs from the rear underside of each chassis member. Note: the offside rubber bung is located in the towing eye.
- Locate item F (Captive Clamp Plates) into each square hole. Using the 'flexi' strap, trap the captive plate centrally into position.
- Using item L with item S, loosely bolt item D (L/H Chassis Bracket) and item E (R/H Chassis Bracket) to item B and item C.
- Using item K with item S, loosely bolt item E up through the towing eye and into the captive clamp plate already in position, using Item V (Spacer Tube) as a spacer.
- Using item L with item S, loosely bolt item D up through the chassis into the captive clamp plate already in position.
- Using item H (Bolts & Nuts), bolt the ball bracket and wiring plate (not supplied in this kit) to the mounting plate.
- Fully tighten all nuts and bolts. Ensure the towbar is rigid and secure.
- Replace the rear bumper using existing fixings, and item N (M6 Nuts) through the bumper brackets on the towbar.
- Reconnect reversing sensors (if fitted).
Note: Nose load limits and vehicle manufacturers' trailer/caravan weight limits must be observed.
MAXI VAN SPECIFIC INSTRUCTIONS
For Maxi Van models, follow these additional steps:
- The forward-most mounting point on each chassis is missing. Fit Item A (Crossmember) to the back panel as per the general instruction. Loosely fit Item B (L/H Side Arm) and Item C (R/H Side Arm) and mark the forward-most mount. Remove Item B and Item C.
- Drill the marked-off holes to 14mm. Open one face of each hole only to 20mm. Insert Item T (Spacer Tubes) and fit the bar as per the general instruction.
Diagram Descriptions
Main Towbar Assembly Diagram: This diagram illustrates the overall structure of the TP3 towbar. It shows the main crossmember (A) connecting to the vehicle chassis via side arms (B, C) and chassis brackets (D, E). Captive clamp plates (F) are shown positioned within the chassis frame, secured by various bolts, nuts, and washers (items H through V). The coupling spacer (G) is also depicted. The diagram highlights how the towbar assembly integrates with the vehicle's rear chassis members and the area where the bumper beam was removed.
Bumper Cutout Diagram: This diagram provides dimensions and guidance for modifying the vehicle's rear bumper. It indicates a specific area to be cut from the lower edge of the bumper to allow the towbar to pass through. Key measurements are shown, including 277mm, 447mm, and 618mm, defining the extent of the 'Bumper Cutout' and 'Lower Edge'. It also labels 'Bumper Tag' indicating a specific point or feature related to the bumper.
