GDW Tow Bar Installation Guide
Hyundai Santa Fe (2000 - ....)
Reference: 1299
EEC APPROVAL N°: e6*94/20*0301*01
D/S/Max: 12,50 KN / 90 Kg / 2500 Kg
Manufacturer: GDW nv
Address: Hoogmolenwegel 23, B-8790 Waregem
Contact: TEL. 32(0)56 60 42 12(5) | FAX. 32(0)56 60 01 93 | Email: gdw@gdwtowbars.com | Website: www.gdwtowbars.com
Installation Instructions
Step 1: Preparation
Remove the spare wheel. Remove the two rear towing rings. On both sides of the vehicle, disassemble the support beam that fastens the bumper support to the chassis.
Step 2: Mount Main Brackets
Place mounting pieces (-g) and (-h) with points (A) and (B) against the underside of the chassis and points (C) and (D) against the outside of the chassis. Points (A), (B), and (D) align with pre-existing threaded holes in the chassis. Point (C) requires an ordinary drilling. At point (C), place a 40x35x12x4 washer on the inside. Insert bolts and washers, but do not tighten yet.
Step 3: Mount Side Brackets
Place mounting pieces (-e) and (-f) with points (I) against the underside of the chassis as shown in the diagram. Detail 1 applies to the right side of the vehicle; the left side is opposite. Points (I) also align with pre-existing threaded holes in the chassis beam. Insert bolts and washers, but do not tighten yet.
Step 4: Bumper Modification and Tow Bar Attachment
Make an incision in the bumper as indicated in sketch X. The mark 'm' corresponds to the center of the bumper. Now, attach the tow bar so that points (E) and (E') of the tow bar align with the corresponding points on the mounting pieces. Tighten all fasteners securely.
Step 5: Final Assembly
Mount the component labeled (*) and replace the spare wheel.
Composition (Parts List)
| Part Description | Reference/Label |
|---|---|
| 1 tow bar reference 1299 | (*-*) |
| 1 ball T43K004 | (E-*-*) |
| 6 bolts M12x40 | (E') |
| 2 bolts M12x45 | (I) |
| 2 bolts M12x110 | (C) |
| 4 bolts M12x1,25x30 | (B-D) |
| 6 bolts M10x1,25x30 | (A-I) |
| 6 nuts M12 | (*-C-E') |
| 14 security washers M12 | (*-*-E-E'-D-C-B) |
| 4 security washers M10 | (A-B) |
| 2 washers 40x35x12x4 | (C) |
| 12 washers 40x35x12x2 | (A-B-C-D-I) |
| 1 mounting piece (-e) | (I-E') |
| 1 mounting piece (-f) | (I-E') |
| 1 mounting piece (-g) | (A-B-C-D-E-E') |
| 1 mounting piece (-h) | (A-B-C-D-E-E') |
| 1 plate (P03) | (*) |
| 4 washers 10,5x20x2mm | (I) |
| 1 security shackle | (*-*) |
| All bolts and nuts: quality 8.8 | |
Technical Diagrams and Specifications
Assembly Diagram
This diagram illustrates the tow bar assembly. It shows the main tow bar structure connecting to the vehicle chassis via mounting pieces labeled (-e), (-f), (-g), and (-h). These pieces attach at various points denoted by letters (A, B, C, D, I) to the chassis and potentially the bumper support. The tow ball assembly (T43K004) and a safety shackle are also depicted, connecting to the main tow bar structure at points (E) and (E'). The diagram uses reference labels for each component and connection point.
Bumper Cut-out Diagram
This diagram details the necessary modification to the vehicle's rear bumper. It shows a section of the bumper marked with 'X' and 'M', where 'M' indicates the center line. A cut-out is required, described as a slot with a width of 40mm. The attachment points for the tow bar are indicated to be 134mm apart, with a depth of 14mm for the cut-out.
Clearance Specifications
These diagrams specify the required clearance zones around the tow bar coupling and ball, adhering to European directive 94/20/EG (Appendix VII, Diagram 30).
The first diagram (A-A) illustrates clearance angles and distances around the tow bar's connection to the vehicle. It shows maximum angles of 30° and 45° for various approach and departure paths, with minimum clearance distances specified for different points (e.g., min. 32mm, min. 55mm, min. 65mm, max. 100mm, min. 140mm). A vertical clearance range of 350-420mm is also indicated.
The second diagram focuses on clearance around the tow ball itself, showing maximum radii (max. R14.5, max. R40) and minimum distances (min. 75mm) with specific angles (max. 30°). These clearances are to be maintained at the vehicle's laden weight or permissible total weight.
Torque Specifications
| Bolts - Boulons - Bolts - Schrauben (Quality 8.8) | Bolts - Boulons - Bolts - Schrauben (Quality 10.9) | ||||
|---|---|---|---|---|---|
| Size | Torque (Nm / kgm) | DIN Standard | Size | Torque (Nm / kgm) | DIN Standard |
| M6 | 10,8Nm / 1,1kgm | DIN 912 - DIN 931 - DIN 933 - DIN 7991 | M6 | 13,7Nm / 1,4kgm | DIN 912 - DIN 931 - DIN 933 - DIN 7991 |
| M12 | 88,3Nm / 9,0kgm | M12 | 122,6Nm / 12,5kgm | ||
| M8 | 25,5Nm / 2,60kgm | M8 | 35,3Nm / 3,6kgm | ||
| M14 | 137Nm / 14,0kgm | M14 | 194Nm / 19,8kgm | ||
| M10 | 52,0Nm / 5,30kgm | M10 | 70,6Nm / 7,20kgm | ||
| M16 | 211,0Nm / 21,5kgm | M16 | 299,2Nm / 30,5kgm | ||
Important Notes
- For the maximum permissible towing mass for your vehicle, consult your vehicle dealer or owner's manual.
- Remove any bitumen coating or anti-vibration material from the fastening points before installation.
- When drilling, be careful not to damage any brake lines, electrical wiring, or fuel lines.
