GDW Tow Bar for Audi A8 (2003-...)
Model: GDW Ref. 1489
EEC Approval: e6*94/20*0548*00
Manufacturer Information
GDW nv
Hoogmolenwegel 23
B-8790 Waregem
TEL: +32(0)56 60 42 12
FAX: +32(0)56 60 01 93
Email: gdw@gdwtowbars.com
Website: www.gdwtowbars.com
Product Description
This document provides installation instructions for the GDW tow bar system, specifically the T36 Escamotable type, for the Audi A8 model manufactured from 2003 onwards.
Mounting Instructions
Step 1: Disassembly
Remove the rear bumper, exhaust system, and heat shields. Disassemble the floor and side coverings inside the trunk. Permanently remove the aluminum buffer beam from the rear of the vehicle.
Step 2: Chassis Preparation and Arm Installation
Slide the supporting arms (2 and 3) approximately 20cm into the chassis beams through the openings created after removing the aluminum buffer beam. Insert the heightening pieces (1) into the chassis beams, positioning them on the tubes welded to the supporting arms at points (A). Secure these heightening pieces to the supporting arms (2 and 3) using M6 bolts. Slide the supporting arms until they align with the existing drillings in the chassis beam. These drillings are sealed with adhesive tape at the bottom of the chassis beam; remove this tape. Attach the nut pieces (4 and 5) to the underside of the chassis beam, against the chassis beam, and fasten them using the supplied rivets. The drillings for these rivets are located precisely before the drillings for points (A). Points (B) align with the rear of the bodywork on existing drillings where the aluminum buffer beam was previously attached. Insert bolts and washers at points (A) and (B) but do not tighten them yet.
Step 3: Tow Bar Attachment
Position the tow bar with points (C) over the supporting arms, ensuring the drillings align. Insert bolts and tighten them securely (refer to torque specifications).
Step 4: Socket Holder Assembly
Assemble the multi-plug socket holder according to the instructions provided with that component.
Step 5: Bumper Modification and Re-installation
Make a cut in the lower part of the bumper following the provided stencil. Re-mount the bumper onto the vehicle.
Step 6: Final Assembly
Mount the ball joint, socket holder, and security shackle onto the tow bar. Tighten all components securely (refer to torque specifications).
Bumper Disassembly Details
- 2x3 screws at the bottom of the splashguards.
- 4 screws at the bottom center of the bumper.
- 2x1 screw inside the trunk, beneath the rear light units.
- Inside the trunk, in the corners, loosen white plastic nuts with an Allen key until the bumper detaches.
- Release the sides at the bottom of the bumper.
Parts List (GDW Ref. 1489)
| Item | Quantity | Description | Reference Code |
|---|---|---|---|
| 1 | 1 | Ball Joint T45M002 | |
| 2 | 4 | Security Nuts M12 DIN985 | (*) |
| 3 | 2 | Bolts M12x70 DIN931 | (*-*) |
| 4 | 2 | Bolts M12x65 DIN931 | (*) |
| 5 | 1 | Security Shackle | (*) |
| 6 | 2 | Pieces T45 | (*-*) |
| 7 | 2 | Tubes T45 | (*) |
| 8 | 2 | Bolts M10x140 DIN931 | (A) |
| 9 | 6 | Security Washers M10 DIN128A | (A-C) |
| 10 | 10 | Washers 40x35x12x4mm | (A-C) |
| 11 | 8 | Bolts M8x35 DIN933 | (B) |
| 12 | 8 | Security Washers M8 DIN128A | (B) |
| 13 | 8 | Washers 25x8.4x2mm | (B) |
| 14 | 4 | Bolts M10x110 DIN931 | (C) |
| 15 | 4 | Nuts M10 DIN934 | (C) |
| 16 | 2 | Bolts M6x10 DIN933 | (D) |
| 17 | 2 | Security Washers M6 DIN128A | (D) |
| 18 | 4 | Rivets DIN7337A (4.8x12mm) | (E) |
| 19 | 1 | Socket Holder P11 | (*') |
| 20 | 2 | Nut pieces (left 5 and right 4) | (A) |
| 21 | 2 | Heightening pieces (left and right 1) | (A-D) |
| 22 | 2 | Supporting arms (left 3 and right 2) | (B-C) |
Technical Specifications
Torque Specifications (All Bolts and Nuts: Quality 8.8)
| Bolt Size | Torque (Nm) | Torque (kgm) | Bolt Size | Torque (Nm) | Torque (kgm) |
|---|---|---|---|---|---|
| M6 | 10.8 | 1.1 | M8 | 25.5 | 2.60 |
| M12 | 88.3 | 9.0 | M10 | 52.0 | 5.30 |
| M14 | 137 | 14.0 | |||
| M16 | 211.0 | 21.5 |
Torque Specifications (All Bolts and Nuts: Quality 10.9)
| Bolt Size | Torque (Nm) | Torque (kgm) | Bolt Size | Torque (Nm) | Torque (kgm) |
|---|---|---|---|---|---|
| M6 | 13.7 | 1.4 | M8 | 35.3 | 3.6 |
| M12 | 122.6 | 12.5 | M10 | 70.6 | 7.20 |
| M14 | 194 | 19.8 | |||
| M16 | 299.2 | 30.5 |
Bumper Cut-out Dimensions
The diagram on page 7 illustrates the required bumper cut-out. The total area to be cut is 205mm in length and 85mm in height. Within this area, a central section of 135mm length and 100mm height is to be removed. This central cut is positioned with 30mm clearance from one edge and 40mm from the other edge along the length.
Clearance Requirements
The clearance must comply with Supplement VII, diagram 30 of guideline 94/20/EG. This ensures proper functionality and safety according to European directives.
Important Notes
- For the maximum permissible towing weight for your vehicle, consult your vehicle's dealer or owner's manual.
- Remove any bitumen coating or anti-drumming material from the areas where the tow bar will be mounted.
- Exercise caution when drilling to avoid damaging any brake lines, electrical wiring, or fuel lines.
