ford Territory Towbar Fitting Instruction Part - Milford Auto · FORD TERRITORY TOWBAR FITTING...

Page No. 1 of 13 Issue A: 07/11 191875FI

FORD TERRITORY TOWBAR FITTING INSTRUCTION

Part # 191875 VEHICLE YEARS OF MANUFACTURE - From May 2004 -

www.milford-auto.com ©

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 1.5 Hours

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.

• Imperial A/F Hex Sockets • Imperial A/F Spanners • Phillips head screwdriver • Trim removal tools • Metal panel cutting tools • Bumper cutting tools • Metal File • Cotton Bud (rust preventative applicator)

• Socket wrench • Metric Hex Sockets • Metric Spanners • Torque wrench • Touch up paint • Side Cutters • Power Drill • Drill Bits—10mm, 14mm

FASTENER TORQUES Fastener size Fastener grade/class Recommended torque

1/2” UNC 8 125Nm/92lbft

M10 x 1.5 8.8 44Nm/32lbft

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) 191890 1

2 Towing Lug (See page 3) 191229 1

3 ‘D’ Shackle (chain connection) 191149 2

4 Bolt—1/2” UNC x 1½” HT ZP 913149 2

5 Hex Nut 1/2” UNC ZP 913155 6

6 Washer—Flat 1/2” ZP 932045 6

7 Washer—Spring 1/2” ZP 913152 6

8 Bolt—M10 x 50 HT ZP 913667 4

12 Washer—Spring 10mm ZP 932010 8

18 Bolt/Plate/Wire ASM (Short—RH, Long—LH) 190171 1x2

16 Angle Bracket—(Short) (RH) 779490 1

13 Bolt/Washer/Wire ASM (M10) ZP 190173 1x2

11 Washer—Flat 10mm ZP 932005 14

10 Hex Nut—M10 ZP 922140 8

14 Rust Preventative Sealer (Sachet) 906300 1

15 Adhesive Label—Identification/Tow bar information

905026 1

17 Angle Bracket—(Long) (LH) 779484 1

9 Bolt—M10 x 35 HT ZP 912075 2

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.

17

18

Items 17 & 18 shown at reduced

scale

TOWBAR INFORMATION

RUST PREVENTATIVE

SEALER

3 4 5 6

12

7 8 9 10 11

13 14

15 16





18

5

2

4

8

Vehicle chassis rail (cut away)

3

7

5

Back panel/member of vehicle

10

6

6

7

5

11

13

Lug retaining pin

‘R’ Clip

12

8

1

10

12

11 10

11

12

x2

17

Item Component Name

1 Towbar ASM

2 Towing Lug

3 ‘D’ Shackle (chain connection)

4 Bolt—1/2” UNC x 1½” HT ZP

5 Hex Nut 1/2” UNC ZP

6 Washer—Flat 1/2” ZP

7 Washer—Spring 1/2” ZP

8 Bolt—M10 x 50 HT ZP

Item Component Name

9 Bolt—M10 x 35 HT ZP

10 Hex Nut—M10 ZP

11 Washer—Flat 10mm ZP

12 Washer—Spring 10mm ZP

13 Bolt/Washer/Wire ASM (M10) ZP

16 Angle Bracket—(Short) (RH)

17 Angle Bracket—(Long) (LH)

18 Bolt/Plate/Wire ASM (Short—RH, Long—LH)

9

18

5

6

7

12 11

11

13

8

8

11

11

RHS

10 16





REMOVE REAR TAIL LIGHTS

1. Open tailgate and locate the 2 screws securing each of the tail lights in place.

2. Remove these screws and also the screw securing the bumper under the tail light.

3. Using a plastic trim removal tool or similar, carefully leaver the tail light rearwards to the vehicle, to release it from concealed retaining clips.

4. Disconnect wiring loom from tail light assembly and store tail light in a safe place.

5. Repeat steps 3 & 4 on other side.

Remove screws

indicated





REMOVE REAR BUMPER BAR

6. Remove the 5 clips securing the bottom rear edge of the bumper to the vehicle.

7. Remove clip securing the bottom of the bumper to the vehicle just behind the rear wheel.

8. Repeat on other side.

9. Remove the screw & 2 clips securing the bumper inside the wheel arch.

10. For May 2011 vehicles onward also remove the clip at the top front edge of the bumper. (Push wheel arch trim out of way to access)

11. Repeat on other side. Note: Additional fasteners may be present if mud flaps have been installed.

Remove clip

Remove clips

Remove screw

Remove 5 clips

Additional clip for May 2011 onward models





REMOVE REAR BUMPER BAR—Continued

13. For pre May 2011 models remove screw securing bumper to vehicle located at the outside bottom of the tail light area.

14. For post May 2011 models carefully release the double clips at the top edge of the bumper in the bottom of the tail light area.


16. With all fasteners removed & clips released, carefully remove bumper from vehicle.

Note: If the vehicle is fitted with reverse parking sensors, the wiring harness connection will need to be disconnected before the bumper can be removed. 17. Store bumper bar in a safe

place until ready for marking/trimming for towbar opening.

INSTALLATION OF THE TOW BAR TO THE VEHICLE CHASSIS

18. Familiarise yourself with the existing mounting points which will be used to secure towbar to vehicle chassis.

Remove screw

Pre May 2011

Post May 2011

Release clips

12. Carefully pull the sides of bumper outwards to release sides from concealed clips.





19. On the LHS of vehicle back panel locate the existing rectangular hole shown.

20. From this hole mark out the back panel as shown.

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

23. Using a jig saw or other suitable tool cut away the marked areas.

24. Using suitable file clean up rough edges.

25. Using suitable touch up paint, such as zinc rich primer, paint the raw edges of the cut area.

60mm

30mm

Cross member flange

21. On the RHS of vehicle back panel locate the existing rectangular hole shown.

22. From this hole mark out the back panel as shown.

30mm

LHS

RHS






26. Remove the towbar tongue from the towbar assembly.

27. With the long towbar side bracket to the LHS of the vehicle, slide the side brackets into the new access holes cut out at step 21.

28. Locate the towbar end brackets over the vehicle rear cross member ends as shown.

29. On RHS place M10 bolt (Item 8) with flat washer (Item 11) under head through rearmost side hole in rear cross member & towbar.

30. Secure bolt in place as shown using flat washer, spring washer & M10 hex nut. Leave loose at this stage.


32. At the rearmost bottom holes in rear cross member ends, place M10 bolt (Item 8) with flat washer (Item 11) under head through hole & towbar bracket.

33. Secure bolts in place as shown using flat washer, spring washer & M10 hex nut. Leave loose at this stage.

34. Cut Bolt/Washer/Wire ASM (Item 13) in half.

35. At the forward most side holes in rear cross member ends place M10 Bolt/Washer/Wire ASM (Item 13) through hole and towbar bracket.

36. Secure bolts in place as shown using flat washer, spring washer & M10 hex nut.

37. Starting with bottom bolts semi tighten the 6x M10 bolts to position the towbar .

Items 8, 11x2, 12 & 10

Items 8, 11x2, 12 & 10

Items 13, 11, 12 & 10

Feed wire—(Item 13)






38. Attach long angle bracket (Item 17) to LH side towbar bracket as shown, using 1/2” UNC bolts (Item 4, flat washers, spring washers & 1/2” UNC hex nuts. Finger tighten only at this stage.

40. Attach short angle bracket (Item 16) to RH side towbar bracket as shown, using M10 x 35mm bolts (Item 9), flat washers, spring washers & M10 hex nuts. Finger tighten only at this stage.

Item 17

Items 4, 6, 7 & 5

41. With brackets pushed up hard against chassis & using the angle brackets as a drill guide, drill 4x 14mm holes through the chassis rail bottom surfaces only.

42. Apply rust preventative sealer (Item 14) to drilled holes.

39. On RHS side of vehicle above exhaust muffler, flatten the back edge of heat shield in the vicinity of the towbar bracket as shown.

Item 16

Items 9, 11x2 each bolt, 12 & 10

Extended drill bit may be required





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

48. Torque up all nuts and bolts as specified in table on page 1.

49. Cut off excess feed wire from items 13 & 18 to prevent rattles.

46. On RHS pass the short Bolt/Plate/Wire ASM down the inside of the chassis rail, then locate the 2 bolts through the 2 holes drilled at step 39 & angle bracket.

47. On underside of vehicle secure angle bracket in place using flat washers, spring washers & 1/2” UNC hex nuts.

43. Cut Bolt/Plate/Wire ASM (Item 18) in half.

44. On LHS pass the long Bolt/Plate/Wire ASM down the inside of the chassis rail, then locate the 2 bolts through the 2 holes drilled at step 39 & angle bracket.

45. On underside of vehicle secure angle bracket in place using flat washers, spring washers & 1/2” UNC hex nuts.

Refer page 3 for installation detail

Refer page 3 for installation detail





CUT REAR BUMPER TO FIT OVER TOWING LUG

51. Using suitable cutting tools remove the centre section marked out at step 50. Hint– Drill approx. 10mm holes in the corners to cut into, giving a better finish.

52. Carefully clean up edge after cutting.

50. Using the mould form lines at the centre bottom edge of bumper bar as datum lines, carefully mark out the centre bottom edge of the rear bumper as shown.

Note: Inside face of bumper shown.

20mm

Bottom edge of bumper

75mm

For vehicles from May 2004 to April 2011

For vehicles from May 2011 to Onward

53. Using the mould form lines at the centre bottom edge of bumper bar as datum lines, carefully mark out the centre bottom edge of the rear bumper as shown.

Note: Inside face of bumper shown.

Do not use trim plug hole to find bumper centre line.

54. Using suitable cutting tools remove the centre section marked out at step 50. Hint– Drill approx. 10mm holes in the corners to cut into, giving a better finish.

55. Carefully clean up edge after cutting.

70mm

120mm

30mm

(115

mm

)





57. Carefully slide the towbar cut out in the bumper bar over the towbar hitch receiver, then reinstall the rear bumper to the vehicle in reverse order to the removal process.

Note: Remember to reconnect the parking sensor wiring if applicable.

RE-ASSEMBLE ALL PARTS TO VEHICLE

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

58. Re-assemble all other items to the vehicle in reverse order to their removal.

ASSEMBLE TOWING LUG TO TOWBAR

59. Fit Milford-Auto hitch receiver cover to towbar if purchased by customer. (Not included with this package)

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

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





62. Affix towbar information label (Item 15) 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

Item 15

Towbar installation complete.

ford Territory Towbar Fitting Instruction Part - Milford Auto · FORD TERRITORY TOWBAR FITTING...

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