ford ranger/mazda bt50 towbar fitting instruction part # · pdf file ·...

Page No. 1 of 8 Issue B: 12/11 191900 FI www.milford-auto.com ©

FORD RANGER/MAZDA BT50 TOWBAR FITTING INSTRUCTION

Part # 191900 VEHICLE YEARS OF MANUFACTURE - From Oct./Nov. 2011

Suitable for all 4x2 Hi Rider, and all 4x4 models

The installation kit contains sufficient components for fitment*. Do not substitute any components. A high degree of technical competence is necessary to correctly install this product. We recommend this towbar be installed by an authorised outlet to ensure the installation complies with the requirements of AS 4177.1 Standard and ADR 62/00. These instructions must be read and clearly understood before commencing installation. *Note: Towbar package does not include any electrical components or mounting bracket for trailer socket.

Installation time - Approximately 1 Hour

(Note: Some parts of install may require 2 persons)

WARNINGS

• The maximum towbar capacity may exceed the maximum allowable towing capacity of some vehicles. For model specific towing capacities and towball download specifications, please refer to the vehicle owners handbook or the manufacturer. Overloading can be dangerous and void your warranties.

• We recommend the use of a tow ball manufactured to comply with AS 4177.2. • Strict compliance with fitting instructions is essential for this product to meet its rated

capacity.

• Do not modify towbar in any way.

• Do not use this towbar on any other vehicle for which it is not designed.

• Modifications to the tow bar or its fixings or use on any other vehicle for which it is not designed may void the load rating and warranty.

• Where high tensile threaded fasteners are used, the towbar must be installed using the size and grade fasteners specified by Milford Industries.

• Do not remove the towbar information label from the towbar. • To comply with ADR 42/00 clause 42.9 the towing lug should be removed when not in use.

FASTENER TORQUES

Fastener size Fastener grade/class Recommended torque

M12 X 1.75 10.9 109Nm/81lbft

• Torque wrench

• Small flat screwdriver

• Socket wrench

• Metric Hex Sockets

• Metric Spanners

TOOLS REQUIRED





Parts List Important: Check contents of kit before commencing fitment and report any discrepancies or damage.

Item Component Name Part No. Qty

1 Towbar ASM (See page 3) 191915 1

2 Towing Lug (See page 3) 191230 1

3 ‘D’ Shackle (chain connection) 191149 2

4 Bolt—Hex Head M12 x 1.75 x 40 HT ZP 913034 12

5 Washer—Spring 12mm ZP 913152 16

6 Washer—Flat 12mm ZP 932045 20

7 Hex Nut—M12 x 1.75 ZP 922246 8

8 Bolt & Plate ASM ZP (M12 x 1.75) 779579 2

9 Bolt, Plate & Wire ASM ZP (M12 x 1.75) 779578 2

10 Hex Nut, Plate & Wire ASM (M12 x 1.75) 779577 2

11 Adhesive Label—Identification/Tow bar information

905026 1

ADVICE TO FITTERS

Note: To fit the towbar the following is essential: � Always drill perpendicular to surface (Unless stated otherwise). � A positive drill stop should always be used to prevent accidental damage to hidden panels, fuel lines etc. � Ensure Safety Eye Protection and Gloves are worn as required when using cutting tools. � When drilling/cutting metal panels be very careful of sharp edges, for risk of skin cuts etc. � Care should be taken when applying Rust Preventative sealer to all holes drilled, to negate the possibility of

skin and eye irritation. � Check screws in relevant components by hand before installation. Should there be resistance re-tap threads

and re-check. � Before marking or drilling to install this towbar, check vehicle for LPG conversion & non standard

fuel tanks. Locate tanks and all lines attached and take EXTREME CARE not to damage whilst installing this tow bar.

� Before drilling to install this towbar, check for concealed wiring looms. E.g. towbar, reversing camera, reversing sensor wiring etc.. Relocate before drilling to avoid damage.

CARE SHOULD BE TAKEN NOT TO CROSS THREAD THE FASTENERS DURING INSTALLATION OF

COMPONENTS TO THE VEHICLE. ALL FASTENERS SHOULD BE TIGHTENED TO THE RECOMMENDED TORQUES.

TOWBAR INFORMATION

3 4 5

9 10

11

6 7 8





Item Component Name

1 Towbar ASM

2 Towing Lug

3 ‘D’ Shackle (chain connection)

4 Bolt—Hex Head M12 x 1.75 x 40 HT ZP

5 Washer—Spring 12mm ZP

6 Washer—Flat 12mm ZP

Item Component Name

8 Bolt & Plate ASM ZP (M12 x 1.75)

9 Bolt, Plate & Wire ASM ZP (M12 x 1.75)

10 Hex Nut, Plate & Wire ASM (M12 x 1.75)

11 Adhesive Label—Identification/Tow bar information

7 Hex Nut—M12 x 1.75 ZP

2

9

4

8

6

1

‘R’ clip

Towing Lug Retaining Pin

3

4

5

11

6

7

10

Anti rattle screw

Vehicle chassis with some captive nuts

3

5 6

6

7

Step/Bumper side bracket

(when applicable)

5

5

Optional Milford-Auto Hitch Receiver Cover (Not included with this package)





REMOVE REAR STEP BUMPER (Where applicable)

1. Disconnect & unclip the bumper wiring loom from the LHS of vehicle.

2. Remove the 4 bolts securing the rear step/bumper to the chassis.

3. Remove the step/bumper & place on a soft work surface.

Note: Mounting bolts will not be re used.

INSTALLATION OF THE TOW BAR TO THE VEHICLE CHASSIS

7. Familiarise yourself with the 6 chassis mounting holes each side which will be used to secure the towbar.

Note: 3 of the side holes each side have captive nuts.

Loosen nuts & slide brackets outwards

RESET THE BUMPER BRACKETS TO FIT OVER THE TOWBAR

4. Loosen the 4 nuts securing the bumper brackets to the bumper.

5. Slide the brackets outwards evenly until an inside dimension of approximately 1196mm is achieved.

6. With brackets in correct position tighten securing nuts.

1196mm

Disconnect & unclip wiring

Remove 2 bolts each side





8. Find the midpoint of the installation wire for the bolt/plate/wire ASM (Item 9) & cut in half.

9. Locate the existing 4 rear most holes, in the bottom face of the rearward ends of the chassis rails.

10. Place the bolt/plate/wire ASM’s (Item 9) downward through the forward pair of holes as shown.

12. Manoeuvre towbar assembly into position on the chassis with holes aligned.

Note: Towbar side brackets need to be lifted up and over the spring shackles to get bar into correct position. 13. Place flat washers (Item 6)

& spring washers (Item 5) over vertical bolts then secure with hex nuts (Item 7).

14. Tighten nuts to position towbar ASM against chassis but leave loose enough to allow alignment of other holes.

15. At the forward most captive nuts in chassis sides, place M12 bolts (Item 4) with spring washers (Item 5) & flat washers (Item 6) under heads.

Note: Do not fully tighten at this stage.

INSTALLATION OF THE TOW BAR TO THE VEHICLE CHASSIS—Cont’d

11. Place the bolt/plate ASM’s (Item 8) downward through the rear pair of holes as shown.

FRONT

Items 6, 5 & 7

Items 4, 5 & 6

Item 9

Item 8





16. If applicable relocate the step/bumper back into position on the vehicle, over the top of the towbar ASM.

17. *Place an M12 bolt (Item 4) with flat washer (Item 6) under head, through each of the holes shown.

*Not required if no step/bumper fitted.

18. Place an M12 bolt (Item 4) with spring washer (Item 5)& flat washer (Item 6) under head, through each of the holes shown.

19. Find the midpoint of the installation wire for the nut/plate/wire ASM (Item 10) & cut in half.

20. Place nut/plate inside chassis rails over bolts inserted at step 18.

21. *On each of the rearmost step/bumper bracket bolts placed at step 17, place a flat washer (Item 6) & spring washer (Item 5). Secure the bolts with hex nuts (Item 7).

22. At each of the remaining captive chassis nuts, place an M12 bolt (Item 4) with spring washer (Item 5) & flat washer (Item 6) under head as shown.

Note: If reinstalling XLT style steel step/bumper, use holes circled with spare bolts supplied.

INSTALLATION OF THE TOW BAR TO THE VEHICLE CHASSIS—Cont’d

Items 4, 5 & 6

Item 10

Items 4 & 6

Step/Bumper bracket

Items 6, 5 & 7

Items 4, 5 & 6

XLT step/bumper mount holes





INSTALLATION OF THE TOW BAR TO THE VEHICLE CHASSIS—cont’d

24. With all bolts in position torque up as per fastener torques on page 1.

ASSEMBLE TOWING LUG TO TOWBAR

27. Fit Milford-Auto hitch receiver cover to towbar if purchased by customer. (Refer page 3 for details)

28. Install the towing lug (Item 2) to the towbar and secure in place using lug retaining pin and ’R’ clip supplied.

29. Install ‘D’ shackles (Item 3) to towbar.

23. With all bolts in position gradually tighten to secure towbar ASM. & step/bumper in place.

Note: Ensure step /bumper aligns correctly with spare wheel winder hole, before fully tightening bolts.

26. Reconnect & re clip step/bumper wiring loom.

25. Trim off any installation wire ends from items 9 & 10.

Check step/bumper alignment before tightening bolts





30. Affix towbar information label (Item 11) in a conspicuous location on the inner panel of the drivers door opening.

Note: Ensure panel is free of dirt and grease before applying.

APPLICATION OF ADHESIVE LOAD RATING LABEL

31. Complete any necessary wiring required for this vehicle. (Not included with this package)

Towbar installation complete.

Item 11

ford ranger/mazda bt50 towbar fitting instruction part # · pdf file ·...

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