GDW Tow Bar Installation Manual

Important Advice and General Instructions

Fitting / Montage

• Before starting, check the tow bar for any transport damage and verify it is the correct reference for your vehicle.
• Read the fitting instructions carefully and follow all steps precisely.
• Present the tow bar under the vehicle to check alignment before drilling or making permanent attachments.
• If drilling holes is necessary, ensure no electrical wiring, brake lines, or other essential components are present. Remove any soundproofing or bitumen layers. 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 packages), consult GDW technical service before proceeding to ensure compatibility.
• The tow bar is delivered assembled for storage purposes; disassemble parts as needed before commencing installation.

Guarantee / Garantie

• To determine your vehicle's correct towing capacity, refer to the Certificate of Conformity (COC) or contact your vehicle dealer. Do not exceed the specifications of the tow bar.
• The tow bar must be checked after the first 1,000 km of use and at least once annually:
  • Check all bolts and retighten if necessary.
  • Repair any paint damage.
  • Replace any components that have been damaged due to an accident or collision.
  • Grease the internal parts of detachable tow bar systems.

Use / Usage / Gebrauch / Utilisation

• If the towing ball obstructs the license plate or the fog light, it is mandatory to remove the ball when the tow bar is not in use.

Vehicle Compatibility and Technical Specifications

This tow bar is designed for the following vehicle models:

• Peugeot Expert (from 05/2016 onwards)
• Peugeot Traveller (from 04/2016 onwards)
• Citroën Jumpy (from 04/2016 onwards)
• Citroën SpaceTourer (from 04/2016 onwards)
• Toyota ProAce (from 03/2016 onwards)
• Toyota ProAce Verso (from 03/2016 onwards)

Towing Weight Specifications

Refer to your vehicle's Certificate of Conformity (COC) or contact your dealer to verify the maximum trailer weight your car can tow.

D-Value: The D-value is a measure of the towing capacity and is calculated based on vehicle and trailer weights. The specified limit for this tow bar is 13.90 kN.

S-Value (Vertical Load): The maximum permissible vertical load on the towing ball is 120 kg.

Parts List

Tools Required (Examples): Socket wrenches (10, 13, 19), Torx drivers (TX20, TX27).

Installation Steps

Step 1: Vehicle Configuration

Identify your vehicle's configuration regarding sliding doors:

• Vehicles without "hands-free sliding doors" use parts 2 and 10.
• Vehicles with "hands-free sliding doors" use parts 11 and 24.

Step 2: Bumper Status

Determine if the rear bumper needs to be removed:

• Bumper does not need to be demounted (for certain configurations).
• Bumper needs to be demounted (for other configurations).

Step 3: Accessing Mounting Points

Open the rear doors of the vehicle. Access the chassis mounting points. This may involve removing or loosening the rear bumper and potentially accessing areas behind the wheel arch liners.

Tools typically used: Socket wrench (10, 13), Torx driver (TX20).

Step 4: Attaching Main Tow Bar Frame

Position the main tow bar frame (Part 1) to the vehicle's chassis mounting points. Secure it using the specified bolts and washers (e.g., Parts 7, 8, 9, 10, 13). Tighten bolts to a torque of 27.3 Nm.

Tools: Socket wrench (13), Torque wrench.

Step 5: Attaching Side Brackets

Attach the side brackets (Parts 7, 8, 9) to the vehicle's chassis. Ensure correct orientation and secure with bolts and washers. Tighten to 27.3 Nm.

Tools: Socket wrench (13), Torque wrench.

Step 6: Attaching Tow Bar Arm/Neck

Attach the tow bar arm/neck (Part 4) to the main tow bar frame. Use the specified bolts, nuts, and washers (e.g., Parts 5, 6, 19). Tighten to a torque of 93.0 Nm.

Tools: Socket wrench (19), Torque wrench.

Step 7: Repeat for Other Side

Repeat the attachment process for the corresponding components on the other side of the vehicle.

Step 8: Final Frame Assembly

Assemble the main tow bar frame components (Parts 1, 2, 4, 5, 6, 10, 19) to the chassis. Ensure all connections are secure and tighten to the specified torque of 93.0 Nm.

Tools: Socket wrench (10, 19), Torque wrench.

Step 9: Bumper Re-installation (if removed)

If the bumper was removed, re-install it, ensuring it fits correctly around the tow bar assembly. This may involve re-attaching bumper mounting brackets.

Tools: Torx driver (TX20), Socket wrench (10).

Step 10: Final Tow Ball Assembly

Attach the tow ball assembly (Parts A, B, C) to the tow bar receiver. Secure with the provided hardware (e.g., bolts, nuts, washers) and tighten to the specified torque of 93.0 Nm.

Tools: Socket wrench (19), Torque wrench.

Step 11: Clearance Check

Ensure all clearances meet the requirements specified in Regulation No. 55, Appendix VII, Diagram 25 (a,b). This includes specific angles and distances related to the tow ball and vehicle chassis.

Key dimensions and angles to consider: 140mm, 32mm, 100mm, 65mm, 45°, 30°, 15°.

These clearances must be maintained at the vehicle's permissible total weight.

Options

This section refers to available options for the tow bar system. It includes a diagram of the tow ball and hitch mechanism, along with a warning symbol ⚠️ and a reference to GDW documentation ?.