Hayman Reese 03395RW Installation Instructions Manual

TOWBAR
INSTALLATION INSTRUCTIONS
PART NUMBER
03395RW
TOYOTA KLUGER GSU/AXUH CL4 – For vehicle built from 03/2021 - ON
PRODUCT DETAILS:
Part Number:
03395RW
Maximum Towing Braked:
2000
kg
ECU Number:
04826
Maximum Towing Unbraked:
750
kg
Tail Harness Length Required:
1800 mm
Maximum Static Ball Load:
200
kg
TBM/Lug Part Number:
21200
Wiring Part Number:
100471-WL
FITTING DETAILS:
Towbar Installation Time:
90 Mins.
Hayman Reese SmartCODE Solution Required:
NO
Wiring Installation Time:
30 Mins.
RPA Disable/Other:
YES
Total Installation Time:
120 Mins.
Bumper Cut Required:
Yes
Note:
• RPA Disable via centre cluster mute option. (See
image step 44.
49-75 Pacific Drive Keysborough, VIC 3173
Phone: 1800 812 017
Email: [email protected]
Rev: A
Page 1
Issue Date: 11-08-2021
TOWBAR
INSTALLATION INSTRUCTIONS
PART NUMBER
03395RW
TOYOTA KLUGER GSU/AXUH CL4 – For vehicle built from 03/2021 - ON
ENSURE THAT INSTRUCTIONS ARE UNDERSTOOD PRIOR TO FITMENT.
BEFORE YOU START:
1.
2.
3.
Hayman Reese recommends that instructions are read completely prior to fitment.
Check all hardware items have been included refer to assembly diagram.
Please ensure this towbar is only fitted to vehicle models as per Hayman Reese application guide
CORRECT
(www.haymanreese.com.au).
4.
Bumper Cuts
5.
Vehicle and bumper variations can and do occur during vehicle manufacture after initial towbar
design. Fitment of towbar to vehicle and accuracy of bumper cut must be assessed prior to any
bumper modifications made. Incorrect bumper cuts are not covered under Hayman Reese warranty.
NOTE: Bumper cuts need to be approached with care, refer to notes below.
•
Bumper centreline – where the centreline of the bumper needs to be determined, the installer
must assess centre point by measurement of bumper width or determining two symmetrical
reference points to give centreline.
•
Bumper edge – To assist with accurate bumper cut measurement, reference to the start of the
bumper edge is now being commonly used.
o Measure from bottom edge along bumper and around corner to the 70 mm point
(Figure 1).
o Do not measure from visible bumper front of corner, upwards (Figure 2).
6.
7.
INCORRECT
Figure 2
Drilling
•
•
8.
Figure 1
For any required drilling during installation, ensure that the area is clear of fuel, electrical & other components that may be
damaged.
All holes drilled into the body panels shall have all burrs & swarf removed then coated with a suitable rust preventative paint.
Bolts/Fasteners
•
•
Ensure that all hardware is fastened to correct torque as specified in this fitting instruction.
All fasteners supplied with this product are used to achieve a specified clamp loading. If replacement is required ensure that
fasteners of the same grade and class are used.
9.
10. NOTE: Achieving correct torque is critical to proper installation and responsibility of the installer. Towbar failures attributed to
tension issues from over tightening or under tightening are not covered by Hayman Reese warranty.
11.
12. Product Labels
a.
b.
Towbar load rating sticker provided with this product shall be conspicuously located on inside rear end of the driver’s door.
Powertrain Control Module (PCM)/Body Control Module (BCM) upgrade warning label will be provided in towbar kit for
vehicles as required. Affix warning label in door and owner’s handbook.
Place Load Rating
sticker inside driver’s
door here
Place Vehicle PCM/ BCM upgrade
warning label in door AND on front
cover of owner’s service handbook
WARNING:
1. 2.
3.
Do not, drill, cut, weld or otherwise modify the towbar.
FOR TOWING PURPOSES ONLY - This towbar is designed and tested by Hayman Reese to adhere to ADR 62/02 which provides
only for the expected load demands of towing.
49-75 Pacific Drive Keysborough, VIC 3173
Phone: 1800 812 017
Email: [email protected]
Rev: A
Page 2
Issue Date: 11-08-2021
TOWBAR
INSTALLATION INSTRUCTIONS
PART NUMBER
03395RW
TOYOTA KLUGER GSU/AXUH CL4 – For vehicle built from 03/2021 - ON
TOWBAR ASSEMBLY DIAGRAM
ITEM
DESCRIPTION
1
2
3
TOYOTA KLUGER WELDED ASSEMBLY
TRAILER BALL MOUNT
SIDE ARM – LHS
4
SIDE ARM – RHS
LAMINATE PLATE LHS
SIDE PLATE – RHS
SET SCREW HEX HD M12x45x1.25P
WASHER PLAIN M14x28x3
NUT HEX HD M12x1.25P
EXHAUST SPACER
BOLT HEX HD M8x40x1.25P
BOLT HEX HD M12x200x1.75P
5
6
7
8
9
10
11
12
QTY
ITEM
DESCRIPTION
QTY
1
1
1
1
13
14
15
NUT HEX HD M12x1.75P
HITCH BOX COLLAR COVER
"D" SHACKLE 10mm
2
1
2
16
1
1
1
16
26
6
1
2
2
17
18
19
20
21
22
23
24
SMART PIN GOLD
TOWBALL 50mm
NUT NYLOC HEX HD M4x0.7P
COMPLIANCE LABEL
DOOR RATING LABEL
HAYMAN REESE LOGO STICKER
PLUG BRACKET
WIRING LOOM
SET SCREW HEX HD M6x16x1.0P
1
2
1
1
1
1
1
1
49-75 Pacific Drive Keysborough, VIC 3173
Phone: 1800 812 017
Email: [email protected]
Rev: A
Page 3
Issue Date: 11-08-2021
TOWBAR
INSTALLATION INSTRUCTIONS
PART NUMBER
03395RW
TOYOTA KLUGER GSU/AXUH CL4 – For vehicle built from 03/2021 - ON
1. Remove the plastic taillight cover.
Repeat for the other side
2. Remove 3x screws.
Pull the taillight rear ward and disconnect any
wiring.
Repeat for the other side
3. Remove 2x screws and 1x scrivet clip.
Repeat for other side.
49-75 Pacific Drive Keysborough, VIC 3173
Phone: 1800 812 017
Email: [email protected]
Rev: A
Page 4
Issue Date: 11-08-2021
TOWBAR
INSTALLATION INSTRUCTIONS
PART NUMBER
03395RW
TOYOTA KLUGER GSU/AXUH CL4 – For vehicle built from 03/2021 - ON
4. Remove 2x screws behind the mud guard.
Remove the mud guard.
Repeat for the other side.
5. Remove 1x screw and 1x scrivet clip.
Peel and remove the wheel arch.
6. Remove 1x bolt, 3x screws and 3x scrivet clips.
Remove underside cover.
49-75 Pacific Drive Keysborough, VIC 3173
Phone: 1800 812 017
Email: [email protected]
Rev: A
Page 5
Issue Date: 11-08-2021
TOWBAR
INSTALLATION INSTRUCTIONS
PART NUMBER
03395RW
TOYOTA KLUGER GSU/AXUH CL4 – For vehicle built from 03/2021 - ON
7. Remove 2x screws, 4x scrivets and 2x plastic nuts.
Remove the underside cover.
8. Remove 2x bolts and the shipping hook
Remove 2x gromets on the side of the chassis.
Repeat for the other side.
9. Unclip the bumper and discount the wiring
located on the RHS of the bumper.
Remove 6x nuts and discard the impact beam.
49-75 Pacific Drive Keysborough, VIC 3173
Phone: 1800 812 017
Email: [email protected]
Rev: A
Page 6
Issue Date: 11-08-2021
TOWBAR
INSTALLATION INSTRUCTIONS
PART NUMBER
03395RW
TOYOTA KLUGER GSU/AXUH CL4 – For vehicle built from 03/2021 - ON
10. Fit the side arm and loosely secure with 3x bolts
and 3x washers.
Repeat for the other side.
11. Fit the cross tube between the side arms and
loosely secure with 2x bolts, 4x washers and 2x
nuts per side.
12. Fit the side plate chassis and loosely secure with
4x bolts, 6x washers and 2x nuts.
Repeat for the other side.
Torque fasteners as follows:
M12 x 1.75P = 77 Nm
M12 x 1.25P = 89 Nm
49-75 Pacific Drive Keysborough, VIC 3173
Phone: 1800 812 017
Email: [email protected]
Rev: A
Page 7
Issue Date: 11-08-2021
TOWBAR
INSTALLATION INSTRUCTIONS
PART NUMBER
03395RW
TOYOTA KLUGER GSU/AXUH CL4 – For vehicle built from 03/2021 - ON
CL
13. Place masking tape on the bumper outer skin
Mark and cut out an area as shown to clear the
hitch box.
80mm
20mm
35mm
200mm
14. On the backside of the Bumper bar, there are
several reinforcement blocks, cut the second
block inboard from the right edge of the Bumper.
Repeat for the other side.
15. Mark and cut out an area 20mm x 60mm.
60mm
60mm
49-75 Pacific Drive Keysborough, VIC 3173
Phone: 1800 812 017
Email: [email protected]
Rev: A
Page 8
Issue Date: 11-08-2021
TOWBAR
INSTALLATION INSTRUCTIONS
PART NUMBER
03395RW
TOYOTA KLUGER GSU/AXUH CL4 – For vehicle built from 03/2021 - ON
16. On the LHS underside trim,
Mark and cut out an area in the hooking hole
60mm
17. On the LHS underside trim,
Mark and cut out an area in the shipping hook
hole to extend 60mm
150m
m
Mark and cut out an area 150mm
18. Locate the plug bracket on the LHS of the tow bar and
ensure the harness cable length is long enough.
Drill 2x ø5mm holes 69mm apart
Remove all swarf and rough edges.
Place the plug bracket on the bumper.
49-75 Pacific Drive Keysborough, VIC 3173
Phone: 1800 812 017
Email: [email protected]
Rev: A
Page 9
Issue Date: 11-08-2021
TOWBAR
INSTALLATION INSTRUCTIONS
PART NUMBER
03395RW
TOYOTA KLUGER GSU/AXUH CL4 – For vehicle built from 03/2021 - ON
19. In the vehicle cabin remove the centre and LHS boot
floor trim.
20. Fold down the second-row seat.
21. Remove the battery cover.
22. Remove the 7x scrivets holding the carpet trim.
23. Remove the 1x M10 nut that secures the tool tray.
24. Remove the tool tray.
25. Remove the LHS compartment trim.
26. Remove rear scuff trim.
49-75 Pacific Drive Keysborough, VIC 3173
Phone: 1800 812 017
Email: [email protected]
Rev: A
Page 10
Issue Date: 11-08-2021
TOWBAR
INSTALLATION INSTRUCTIONS
PART NUMBER
03395RW
TOYOTA KLUGER GSU/AXUH CL4 – For vehicle built from 03/2021 - ON
27. Locate the LHS cargo net hook, twist off cargo to
expose M10 bolt, remove bolt.
28. Locate the LHS cargo anchor hook remove the plastic
trim to and remove the M10 bolt.
29. Dislodge the LHS trim enough to gain access the
trailer 6-way prewire connector.
Note: Care must be taken not to damage the trim.
30. This image is an indication of where the connector
location is behind the trim.
49-75 Pacific Drive Keysborough, VIC 3173
Phone: 1800 812 017
Email: [email protected]
Rev: A
Page 11
Issue Date: 11-08-2021
TOWBAR
INSTALLATION INSTRUCTIONS
PART NUMBER
03395RW
TOYOTA KLUGER GSU/AXUH CL4 – For vehicle built from 03/2021 - ON
31. Locate the trailer prewire 6-way connector which is
taped to the vehicle main harness.
32. Pull the connector rearward to allow ease of
accessibility.
33. Plug in the trailer patch connector to the mating
vehicle connector.
34. Secure the trailer patch ground ring terminal to
vehicle thread with supplied M6 bolt.
35. Clean the area with supplied alcohol wipe in a
suitable area.
36. Apply the double-sided tape to the ECU.
37. Connect the trailer patch 12-way connector to the
ECU (04826).
38. Place the ECU to vehicle sheet metal ensure good
adhesion.
Ensure the ECU is mounted with the connector
pointing downwards to avoid water ingress or
condensation.
39. Locate the blanking grommet in the LHS side rear
cavity and remove.
If the grommet is used drill aø30mm hole file down
and rough edges and spray rust inhibitor.
49-75 Pacific Drive Keysborough, VIC 3173
Phone: 1800 812 017
Email: [email protected]
Rev: A
Page 12
Issue Date: 11-08-2021
TOWBAR
INSTALLATION INSTRUCTIONS
PART NUMBER
03395RW
TOYOTA KLUGER GSU/AXUH CL4 – For vehicle built from 03/2021 - ON
40. From outside the vehicle feed the tail harness
(1200mm) blue connector through the hole and slide
the grommet to desired location ensure the grommet
is seated properly.
41. Secure the grommet with supplied cable tie.
42. Route the tail harness blue connector towards the
trailer patch mating connector.
43. Connect the blue mating connectors.
44. Secure the harness with cable ties, ensure no rattle
or squeaks.
45. Replace all removed parts from steps 1-7 and 19-28
in reverse.
46. To disable RPA the system, when in reverse the
image will come up on the centre cluster and can be
muted by pressing the ok button on the steering
wheel.
47. Place instructions in glovebox when finished.
49-75 Pacific Drive Keysborough, VIC 3173
Phone: 1800 812 017
Email: [email protected]
Rev: A
Page 13
Issue Date: 11-08-2021
CUSTOMER INFORMATION
PLACE THESE INSTRUCTIONS IN THE
VEHICLE’S GLOVEBOX AFTER INSTALLATION
THANK YOU FOR PURCHASING HAYMAN REESE.
WITH CORRECT MAINTENANCE AND CARE THIS PRODUCT WILL PROVIDE A
LIFETIME OF TROUBLE-FREE OPERATION.
TOWBAR MAINTENANCE AND CARE:
1. Hayman Reese recommend that the towbar LUG or TBM (tow ball Mount) Pull Pin and R-clip are removed
and stored when not in use. Removal of LUG or TBM (tow ball mount) is advisable when not in use to
assist with any of the following.
•
•
•
Ensure rear number plate is not obscured.
Allow maximum available departure angle and prevent any potential interference.
Prevent possible interference with vehicles reverse sensors or camera detecting a tow ball mount
as an obstruction during reversing.
• Removes towball mount as an obstruction for when moving around the rear of the vehicle.
2. Hayman Reese recommends routine inspection of your towbar to ensure trouble free towing.
• Bolt security and tension should be regularly inspected and checked for correct tension. Replace
any worn or defective parts with suitable grade & class fasteners. Inspection should be requested
to coincide with vehicle major services.
3. It is the owner’s responsibility to ensure towing and down ball weight capacities of the towing vehicle are
not exceeded.
• Towing and down ball weights allowable may differ according to model variations. Please refer to
owner’s manual or vehicle dealer to confirm exact rating for your vehicle model variant.
• It is not uncommon for the vehicle tow rating to differ from the towbar rating. When this occurs,
the lesser rating must be adhered to.
• For vehicles fitted with enhanced vehicle functions that may be altered/changed when towing i.e
Trailer sway mitigation, blind spot detection, adaptive cruise control etc. Please consult owner’s
manual to understand changes enabled when towing and after towing.
WARRANTY INFORMATION:
Hayman Reese Towbars are covered by a Lifetime Warranty.
Our goods come with guarantees that cannot be excluded under the Australian Consumer Law. You are
entitled to a replacement or refund for a major failure and for compensation for any other reasonably
foreseeable loss or damage. You are also entitled to have the goods repaired or replaced if the goods fail to
be of acceptable quality and the failure does not amount to a major failure.
For further details please visit www.haymanreese.com.au/warranty or contact customer service on
1800 812 017 or [email protected].
49-75 Pacific Drive Keysborough, VIC 3173
Phone: 1800 812 017
Email: [email protected]
Rev: A
Page 14
Issue Date: 11-08-2021
CUSTOMER INFORMATION
PLACE THESE INSTRUCTIONS IN THE
VEHICLE’S GLOVEBOX AFTER INSTALLATION
HAYMAN REESE SMART PIN
Your Hayman Reese towbar is equipped with Smart Pin technology to help reduce towbar tongue rattle in most
driving conditions. Please ensure below instructions are understood and routine maintenance is carried out to
ensure best towing experience.
Regularly inspect for wear and check the tightness of the Smart Pin Nut. Follow instructions below to retighten the nut as necessary when movement and noise in the tow ball mount is noted.
• Before towing, ensure R-Clip is properly installed and Smart pin nut is installed and tensioned.
Replacement parts are available from your Hayman Reese Distributor.
TOWBALL MOUNT REMOVAL/INSTALLATION
HITCHBOX (b)
STEP 1
Insert Trailer Ball Mount (TBM) (a) into towbar
hitchbox (b), aligning hole in TBM shank (c) with
hole in hitchbox (d) (Fig. 1)
TRAILER BALL
MOUNT (a)
STEP 2
(d)
Insert Smart Pin (e) through hole in hitchbox and
hole in TBM shank (g); ensure the locators are
inserted into the notches in the hitchbox (Fig. 2)
(c)
Fig. 1
STEP 3
(g)
Screw Smart Pin Nut (f) onto Smart Pin (g); tighten
Smart Pin Nut until finger tight, ensuring TBM is
restrained from up and down movement.
SMART PIN NUT (f)
SMART PIN (e)
STEP 4
R-CLIP
Tighten Smart Pin Nut by turning nut a further
1/8th of a turn in the clockwise direction using a
24mm spanner (Fig. 4).
Fig. 2
Fig. 3
STEP 5
Install Smart Pin R-Clip through the hole that
provides best clearance or easiest access. (Fig. 5)
Fig. 5
STEP 6
Install towball onto TBM and tighten to 350 Nm
using a calibrated torque wrench (Fig. 6).
Fig. 4
Fig. 6
49-75 Pacific Drive Keysborough, VIC 3173
Phone: 1800 812 017
Email: [email protected]
Rev: A
Page 15
Issue Date: 11-08-2021
TOWBAR
INSTALLATION INSTRUCTIONS
PART NUMBER
03395RW
TOYOTA KLUGER GSU/AXUH CL4 – For vehicles built 03/2014 – 03/2021
PRODUCT DETAILS:
Part Number:
03395RW
Maximum Towing Braked:
2000
kg
ECU Number:
04826
Maximum Towing Unbraked:
700
kg
Tail Harness Length Required:
1200 mm
Maximum Static Ball Load:
200
kg
TBM/Lug Part Number:
21200
Wiring Part Number:
100471-WL
FITTING DETAILS:
Towbar Installation Time:
90 Mins.
Hayman Reese SmartCODE Solution Required:
NO
Wiring Installation Time:
30 Mins.
RPA Disable/Other:
NO
Total Installation Time:
120 Mins.
Bumper Cut Required:
Yes
49-75 Pacific Drive Keysborough, VIC 3173
Phone: 1800 812 017
Email: [email protected]
Rev: A
Page 1
Issue Date: 11-08-2021
TOWBAR
INSTALLATION INSTRUCTIONS
PART NUMBER
03395RW
TOYOTA KLUGER GSU/AXUH CL4 – For vehicles built 03/2014 – 03/2021
ENSURE THAT INSTRUCTIONS ARE UNDERSTOOD PRIOR TO FITMENT.
BEFORE YOU START:
1.
2.
3.
Hayman Reese recommends that instructions are read completely prior to fitment.
Check all hardware items have been included refer to assembly diagram.
Please ensure this towbar is only fitted to vehicle models as per Hayman Reese application guide
CORRECT
(www.haymanreese.com.au).
4.
Bumper Cuts
5.
Vehicle and bumper variations can and do occur during vehicle manufacture after initial towbar
design. Fitment of towbar to vehicle and accuracy of bumper cut must be assessed prior to any
bumper modifications made. Incorrect bumper cuts are not covered under Hayman Reese warranty.
NOTE: Bumper cuts need to be approached with care, refer to notes below.
•
Bumper centreline – where the centreline of the bumper needs to be determined, the installer
must assess centre point by measurement of bumper width or determining two symmetrical
reference points to give centreline.
•
Bumper edge – To assist with accurate bumper cut measurement, reference to the start of the
bumper edge is now being commonly used.
o Measure from bottom edge along bumper and around corner to the 70 mm point
(Figure 1).
o Do not measure from visible bumper front of corner, upwards (Figure 2).
6.
7.
INCORRECT
Figure 2
Drilling
•
•
8.
Figure 1
For any required drilling during installation, ensure that the area is clear of fuel, electrical & other components that may be
damaged.
All holes drilled into the body panels shall have all burrs & swarf removed then coated with a suitable rust preventative paint.
Bolts/Fasteners
•
•
Ensure that all hardware is fastened to correct torque as specified in this fitting instruction.
All fasteners supplied with this product are used to achieve a specified clamp loading. If replacement is required ensure that
fasteners of the same grade and class are used.
9.
10. NOTE: Achieving correct torque is critical to proper installation and responsibility of the installer. Towbar failures attributed to
tension issues from over tightening or under tightening are not covered by Hayman Reese warranty.
11.
12. Product Labels
a.
b.
Towbar load rating sticker provided with this product shall be conspicuously located on inside rear end of the driver’s door.
Powertrain Control Module (PCM)/Body Control Module (BCM) upgrade warning label will be provided in towbar kit for
vehicles as required. Affix warning label in door and owner’s handbook.
Place Load Rating
sticker inside driver’s
door here
Place Vehicle PCM/ BCM upgrade
warning label in door AND on front
cover of owner’s service handbook
WARNING:
1. 2. Do not, drill, cut, weld or otherwise modify the towbar.
3. FOR TOWING PURPOSES ONLY - This towbar is designed and tested by Hayman Reese to adhere to ADR 62/02 which provides
only for the expected load demands of towing.
49-75 Pacific Drive Keysborough, VIC 3173
Phone: 1800 812 017
Email: [email protected]
Rev: A
Page 2
Issue Date: 11-08-2021
TOWBAR
INSTALLATION INSTRUCTIONS
PART NUMBER
03395RW
TOYOTA KLUGER GSU/AXUH CL4 – For vehicles built 03/2014 – 03/2021
TOWBAR ASSEMBLY DIAGRAM
ITEM
QTY
ITEM
1
1
1
1
13
14
15
NUT HEX HD M12x1.75P
HITCH BOX COLLAR COVER
"D" SHACKLE 10mm
2
1
2
4
TOYOTA KLUGER WELDED ASSEMBLY
TRAILER BALL MOUNT
SIDE ARM – LHS
SIDE ARM – RHS
16
SMART PIN GOLD
1
5
6
7
8
9
10
11
12
LAMINATE PLATE LHS
SIDE PLATE – RHS
SET SCREW HEX HD M12x45x1.25P
WASHER PLAIN M14x28x3
NUT HEX HD M12x1.25P
EXHAUST SPACER
BOLT HEX HD M8x40x1.25P
BOLT HEX HD M12x200x1.75P
1
1
16
26
6
1
2
2
17
18
19
20
21
22
23
24
TOWBALL 50mm
NUT NYLOC HEX HD M4x0.7P
COMPLIANCE LABEL
DOOR RATING LABEL
HAYMAN REESE LOGO STICKER
PLUG BRACKET
WIRING LOOM
SET SCREW HEX HD M6x16x1.0P
1
2
1
1
1
1
1
1
1
2
3
DESCRIPTION
DESCRIPTION
QTY
49-75 Pacific Drive Keysborough, VIC 3173
Phone: 1800 812 017
Email: [email protected]
Rev: A
Page 3
Issue Date: 11-08-2021
TOWBAR
INSTALLATION INSTRUCTIONS
PART NUMBER
03395RW
TOYOTA KLUGER GSU/AXUH CL4 – For vehicles built 03/2014 – 03/2021
1. Release the tail gate to expose the boot of the
vehicle.
Remove 3x screws.
Pull the tail light rear ward.
Repeat for the other side.
2. On the inside of the rear guards remove 1x
scrivet clip and 3x Allen Key Head Screws.
Repeat for the other side.
3. Remove 2x screws behind the mud guard.
Remove the mud guard.
Repeat for the other side.
49-75 Pacific Drive Keysborough, VIC 3173
Phone: 1800 812 017
Email: [email protected]
Rev: A
Page 4
Issue Date: 11-08-2021
TOWBAR
INSTALLATION INSTRUCTIONS
PART NUMBER
03395RW
TOYOTA KLUGER GSU/AXUH CL4 – For vehicles built 03/2014 – 03/2021
4. Remove 1x screw and 1x scrivet clip.
Peel and remove the wheel arch.
5. Remove 1x bolt, 3x screws and 3x scrivet clips.
Remove underside cover.
6. Remove 2x screws, 4x scrivets and 2x plastic nuts.
Remove the underside cover.
49-75 Pacific Drive Keysborough, VIC 3173
Phone: 1800 812 017
Email: [email protected]
Rev: A
Page 5
Issue Date: 11-08-2021
TOWBAR
INSTALLATION INSTRUCTIONS
PART NUMBER
03395RW
TOYOTA KLUGER GSU/AXUH CL4 – For vehicles built 03/2014 – 03/2021
7. Remove 2x bolts and the shipping hook
Remove 2x gromets on the side of the chassis.
Repeat for the other side.
8. Unclip the bumper and discount the wiring
located on the RHS of the bumper.
Remove 6x nuts and discard the impact beam.
9. On the Driver side, unbolt the Exhaust Hanger
where it mounts to the inside of the Chassis
Rails. Re-attach Exhaust Hanger with the
exhaust spacer provided and 2x M10x40mm Set
Screws.
49-75 Pacific Drive Keysborough, VIC 3173
Phone: 1800 812 017
Email: [email protected]
Rev: A
Page 6
Issue Date: 11-08-2021
TOWBAR
INSTALLATION INSTRUCTIONS
PART NUMBER
03395RW
TOYOTA KLUGER GSU/AXUH CL4 – For vehicles built 03/2014 – 03/2021
10. On the Driver’s side loosely secure the
corresponding side arm using the vertical
mounts and 3x M12x45 Set Screws on the
chassis rails. See images on Page 3 for
clarification.
Repeat for the other side.
11. Fit the cross tube between the side arms and
loosely secure with 2x bolts, 4x washers and 2x
nuts per side.
12. Fit the side plate chassis and loosely secure with
4x bolts, 6x washers and 2x nuts.
Repeat for the other side.
Torque fasteners as follows:
M12 x 1.75P = 77 Nm
M12 x 1.25P = 89 Nm
49-75 Pacific Drive Keysborough, VIC 3173
Phone: 1800 812 017
Email: [email protected]
Rev: A
Page 7
Issue Date: 11-08-2021
TOWBAR
INSTALLATION INSTRUCTIONS
PART NUMBER
03395RW
TOYOTA KLUGER GSU/AXUH CL4 – For vehicles built 03/2014 – 03/2021
13. Please be advised that this Towbar has very tight
clearances. It is CRITICAL that the spare tyre be
reset. Lower the tyre out of the cradle using the
factory tool kit and push the tyre while it is loose
as far forward (to the front of the vehicle) and reseat it into the cradle. This is will allow for
sufficient clearance to the tow bar and spare tyre.
14. The rear Bumper is a two-piece item with a
bottom garnish. Separate the garnish from the
Bumper. Cut the extended locating flange to
follow the line of the underside of the garnish.
75MM
15. From the centre of the garnish cut approximately
100MM either side and 35MM up from the bottom
of the garnish. Then cut an additional 43MM either
side form the centre of the garnish and 20MM up
from the previous cut. Reattach garnish to the
Bumper.
15MM
35MM
200MM
49-75 Pacific Drive Keysborough, VIC 3173
Phone: 1800 812 017
Email: [email protected]
Rev: A
Page 8
Issue Date: 11-08-2021
TOWBAR
INSTALLATION INSTRUCTIONS
PART NUMBER
03395RW
TOYOTA KLUGER GSU/AXUH CL4 – For vehicles built 03/2014 – 03/2021
16. On the backside of the Bumper bar, there are
several reinforcement blocks, cut the second
block inboard from the driver’s side off by either
trimming with an air saw or die grinder. This is
the second block from the right edge of the
Bumper. Repeat for passenger side of Bumper
bar.
17. On both sides of the underbody trim, where the
factory shipping hook protrudes extend the relief
hold an additional 60MM
60M
M
18. On the left hand side or passenger side underside
trim cut the most rearward inner corner of the
trim to suit.
150M
M
Cut approximately 150MM deep and 100MM wide
all the way through to the relief hole for the
factory Shipping hook.
49-75 Pacific Drive Keysborough, VIC 3173
Phone: 1800 812 017
Email: [email protected]
Rev: A
Page 9
Issue Date: 11-08-2021
TOWBAR
INSTALLATION INSTRUCTIONS
PART NUMBER
03395RW
TOYOTA KLUGER GSU/AXUH CL4 – For vehicles built 03/2014 – 03/2021
19. Locate the plug bracket on the LHS of the tow bar
and ensure the harness cable length is long
enough.
Drill 2x ø5mm holes 69mm apart
Remove all swarf and rough edges.
Place the plug bracket on the bumper.
20. Fold down the rear seats and remove the luggage
compartment floor cover (1) and remove the centre,
LHS and RHS tool trays (not shown).
21. Remove the luggage compartment rear trim (2).
1
2
22. Locate a suitable area in the LHS rear quarter and drill
out the grommet hole (1) to Ø30mm.
23. After drilling, file any rough or sharp edges and spray
on rust inhibitor.
49-75 Pacific Drive Keysborough, VIC 3173
Phone: 1800 812 017
Email: [email protected]
Rev: A
Page 10
Issue Date: 11-08-2021
TOWBAR
INSTALLATION INSTRUCTIONS
PART NUMBER
03395RW
TOYOTA KLUGER GSU/AXUH CL4 – For vehicles built 03/2014 – 03/2021
24. Connect the trailer patch (P/No:100471-WL) breakout connector (1) to the vehicle break-out connector
(2).
25. Secure the trailer patch ground ring terminal (3) to
the vehicle grounding point (4).
26. From outside the vehicle feed the tail harness
(1200mm) blue connector through the hole and slide
the grommet to desired location ensure the grommet
is seated properly.
27. Secure the grommet with supplied cable tie.
28. Route the tail harness blue connector towards the
trailer patch mating connector.
29. Connect the blue mating connectors.
30. Apply double sided tape to the ECU (1) and adhere it
to the outward face of the inner sheet metal on the
RHS of the luggage compartment.
Ensure the ECU is mounted with the connector
pointing downwards as much as possible to avoid
water ingress or condensation.
31. Referring to the fuse panel, locate the 'Towing' fuse
location (1).
Insert the (supplied) 30-amp fuse into the 'Towing'
fuse location (1).
49-75 Pacific Drive Keysborough, VIC 3173
Phone: 1800 812 017
Email: [email protected]
Rev: A
Page 11
Issue Date: 11-08-2021
TOWBAR
INSTALLATION INSTRUCTIONS
PART NUMBER
03395RW
TOYOTA KLUGER GSU/AXUH CL4 – For vehicles built 03/2014 – 03/2021
32. Test the body harness using a light board or
multimeter.
33. Using cable ties (not supplied), secure harnesses
away from any moving parts, sharp edges or hot
surfaces at 200mm intervals.
34. Re-fit all removed parts and secure all fasteners,
ensuring there are no squeaks or rattles following
steps 1-9, 20-21 in reverse.
35. Place the instructions in the glove box after fitment.
49-75 Pacific Drive Keysborough, VIC 3173
Phone: 1800 812 017
Email: [email protected]
Rev: A
Page 12
Issue Date: 11-08-2021
CUSTOMER INFORMATION
PLACE THESE INSTRUCTIONS IN THE
VEHICLE’S GLOVEBOX AFTER INSTALLATION
THANK YOU FOR PURCHASING HAYMAN REESE.
WITH CORRECT MAINTENANCE AND CARE THIS PRODUCT WILL PROVIDE A
LIFETIME OF TROUBLE-FREE OPERATION.
TOWBAR MAINTENANCE AND CARE:
1. Hayman Reese recommend that the towbar LUG or TBM (tow ball Mount) Pull Pin and R-clip are removed
and stored when not in use. Removal of LUG or TBM (tow ball mount) is advisable when not in use to
assist with any of the following.
•
•
•
Ensure rear number plate is not obscured.
Allow maximum available departure angle and prevent any potential interference.
Prevent possible interference with vehicles reverse sensors or camera detecting a tow ball mount
as an obstruction during reversing.
• Removes towball mount as an obstruction for when moving around the rear of the vehicle.
2. Hayman Reese recommends routine inspection of your towbar to ensure trouble free towing.
• Bolt security and tension should be regularly inspected and checked for correct tension. Replace
any worn or defective parts with suitable grade & class fasteners. Inspection should be requested
to coincide with vehicle major services.
3. It is the owner’s responsibility to ensure towing and down ball weight capacities of the towing vehicle are
not exceeded.
• Towing and down ball weights allowable may differ according to model variations. Please refer to
owner’s manual or vehicle dealer to confirm exact rating for your vehicle model variant.
• It is not uncommon for the vehicle tow rating to differ from the towbar rating. When this occurs,
the lesser rating must be adhered to.
• For vehicles fitted with enhanced vehicle functions that may be altered/changed when towing i.e
Trailer sway mitigation, blind spot detection, adaptive cruise control etc. Please consult owner’s
manual to understand changes enabled when towing and after towing.
WARRANTY INFORMATION:
Hayman Reese Towbars are covered by a Lifetime Warranty.
Our goods come with guarantees that cannot be excluded under the Australian Consumer Law. You are
entitled to a replacement or refund for a major failure and for compensation for any other reasonably
foreseeable loss or damage. You are also entitled to have the goods repaired or replaced if the goods fail to
be of acceptable quality and the failure does not amount to a major failure.
For further details please visit www.haymanreese.com.au/warranty or contact customer service on
1800 812 017 or [email protected].
49-75 Pacific Drive Keysborough, VIC 3173
Phone: 1800 812 017
Email: [email protected]
Rev: A
Page 13
Issue Date: 11-08-2021
CUSTOMER INFORMATION
PLACE THESE INSTRUCTIONS IN THE
VEHICLE’S GLOVEBOX AFTER INSTALLATION
HAYMAN REESE SMART PIN
Your Hayman Reese towbar is equipped with Smart Pin technology to help reduce towbar tongue rattle in most
driving conditions. Please ensure below instructions are understood and routine maintenance is carried out to
ensure best towing experience.
Regularly inspect for wear and check the tightness of the Smart Pin Nut. Follow instructions below to retighten the nut as necessary when movement and noise in the tow ball mount is noted.
• Before towing, ensure R-Clip is properly installed and Smart pin nut is installed and tensioned.
Replacement parts are available from your Hayman Reese Distributor.
TOWBALL MOUNT REMOVAL/INSTALLATION
HITCHBOX (b)
STEP 1
Insert Trailer Ball Mount (TBM) (a) into towbar
hitchbox (b), aligning hole in TBM shank (c) with
hole in hitchbox (d) (Fig. 1)
TRAILER BALL
MOUNT (a)
STEP 2
(d)
Insert Smart Pin (e) through hole in hitchbox and
hole in TBM shank (g); ensure the locators are
inserted into the notches in the hitchbox (Fig. 2)
(c)
Fig. 1
STEP 3
(g)
Screw Smart Pin Nut (f) onto Smart Pin (g); tighten
Smart Pin Nut until finger tight, ensuring TBM is
restrained from up and down movement.
SMART PIN NUT (f)
SMART PIN (e)
STEP 4
R-CLIP
Tighten Smart Pin Nut by turning nut a further
1/8th of a turn in the clockwise direction using a
24mm spanner (Fig. 4).
Fig. 2
Fig. 3
STEP 5
Install Smart Pin R-Clip through the hole that
provides best clearance or easiest access. (Fig. 5)
Fig. 5
STEP 6
Install towball onto TBM and tighten to 350 Nm
using a calibrated torque wrench (Fig. 6).
Fig. 4
Fig. 6
49-75 Pacific Drive Keysborough, VIC 3173
Phone: 1800 812 017
Email: [email protected]
Rev: A
Page 14
Issue Date: 11-08-2021