Nov, 2007 Page 1 of 5 www.milfordind.com.au

Toyota Hi-lux SR5 Towbar Fitting Instructions

PART # 690125 YEARS OF MANUFACTURE – April 2005 Onwards

TO SUIT 2WD / 4WD / CAB CHASSIS & TUB BODY VEHICLES

NOTE: WILL FIT VEHICLES WITH STEP OR BUMPER

This package contains sufficient components to fit the towbar, 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 that the towbar installation complies with the requirements of AS/NZS 4177-1. Important: Refer to the vehicle handbook or consult with the vehicle manufacturer to ascertain the maximum towing capacity of this vehicle. Use caution as overloading can be dangerous and may void the manufacturer’s warranty. We recommend the use of a towball rated to AS4177-2

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Note: To fit this towbar the following is essential:

• Prior to installation, please ensure that all components as listed in the

component table at the bottom of this page are assembled together, accounted for & inspected to determine that they are free from any transport damage.

• Please read, understand & follow all installation steps in sequence and as

detailed on the following pages.

• Do not modify this towbar package in any way.

• If installation of this towbar requires welding as part of the installation

sequence, please refer to the vehicle manufacturers handbook or consult directly with the vehicle manufacturer to ensure that welding to the vehicle will not interfere and / or damage any onboard electronic or computer systems before proceeding with installation.

• A positive drill stop should always be used to prevent accidental damage

to external panels, fuel lines etc.

• Always drill perpendicular to surface (Unless stated otherwise).

• Care should be taken when applying Tekote Sealer/Rust Preventative 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.

• All fasteners should be tightened in accordance with the recommendations

contained within the Fastener Torque Table below

• Before marking or drilling for this Towbar, check vehicle for LPG

Conversion. If LPG is fitted, locate gas unit and all lines attached and take extreme care whilst installing this Towbar.

• Care Should be taken not to cross thread the fasteners during installation

of components to the vehicle.

• Torque Wrench • Screwdriver • Assorted Wrenches &

sockets • Pliers

Fastener Torque Table These Torque Values are intended to be used as a guide only—check with the bolt manufacturer for the latest and most up to date values.

Bolt Diameter Size / Position Grade or Class Max Torque — Nm

M12 40 10.9 125

3/8” UNC 1 1/4” 5 36

1/2” UNC Bolt plate assembly 8 125

Component Listing

Qty Description Qty Description

1 Towbar tongue 1 1 1/4” X 3/8” zinc bolt

2 Shackles 8 M12 x 40 x 1.25

2 Rating Labels 1 3/8” zinc nut

12 1/2” Flat Washers 4 1/2” zinc nuts

12 1/2” Spring Washers 2 Plates & 1/2” bolt wire assemblies

1 Hitch Pin 4 Spacer Tube

1 Hitch Pin Clip

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Toyota Hi-lux SR5 PN 690125

INSTALLATION OF TOW BAR INSTALLATION OF TOW BAR

2. Locate mounting point on chassis • Locate tapped holes in the

vehicle chassis, as shown in picture.

3 . Align towbar • Distinguish mounting

hole’s on towbar ( as shown in picture)

• Offer Tow Bar to chassis aligning holes on bar to those shown in step 2.

Captive Nuts

To Captive nuts

Mounting holes

To mounting holes

1. Remove rear step • Locate the two M12 bolts fixing

the rear step to the chassis and remove

• Repeat for other side and remove step

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Toyota Hi-lux SR5 PN 690125

4. Fasten towbar • Using M12 bolt 1/2 inch spring

washer and 1/2 inch flat washer fasten towbar to tapped hole closest to tray support do not fully tighten bolt

• Repeat for opposite side

5. Mounting plate installation • Feed 2 x prepared mounting

plate assembly down through existing holes in chassis rail.

• Repeat for opposite side

6. Attaching mounting plate • Using 1/2 inch spring washer

and 1/2 inch UNC nut finger tighten onto the threaded pin on the mounting plate assemblyprotruding through chassis rail.

• Repeat for opposite side.

WARNING: All nuts and bolt’s must be finger tight at this point to ensure the correct alignment of the Tow Bar and reduce the risk of damage to threads.

NOTE: This picture is taken from the underside of the vehicle.

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Toyota Hi-lux SR5 PN 690125

7. Prepare rear step • Remove two bolts that fix the

bumper mounting bracket to the bumper on each side.

• Replace the old bolts with the M12 supplied along with a flat and spring washer, place the spacer tube between the bumper and mounting bracket as shown in picture.

• Repeat for opposite side

8. Step installation • Offer prepared step to original

mounting points using the bolt from operation 4 to locate, use supplied M12 spring and flat washer to fix the last mounting point to step and towbar .

• Repeat for opposite side

WARNING: All nuts and bolt’s must be finger tight at this point to ensure the correct alignment of the Tow Bar and reduce the risk of damage to threads.

Spacer

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Toyota Hi-lux SR5 PN 690125

9. Tightening towbar assembly • Tighten the M12 Bolts to

specified Torque setting ( 125 Nm).

• Repeat opposite side. • Tighten the 1/2 inch UNC Nuts

to specified torque setting ( 125 Nm).

• Repeat for opposite side. NOTE: Care should be taken to ensure the Nuts and Bolts are tightened to specific torque settings.

Rating Label Location

WHEN TOWBAR INSTALLATION IS COMPLETE, FITTER MUST APPLY RATING LABEL AS

PER THE LOCATION IN THE ILLUSTRATION BELOW

CHECK THAT ALL BOLTS, NUTS AND SCREWS ARE TIGHT WHEN FITTING COMPLETE

Rating label