Hayman Reese 03294XW User manual

TOWBAR
INSTALLATION INSTRUCTIONS
PART NUMBER
03294XW
FORD RANGER PX X-BAR
49-75 Pacific Drive Keysborough, VIC 3173
Phone: [phone]
Email: [e-mail]
Rev: BPage 1Issue Date: 13-02-20
PRODUCT DETAILS:
Part Number:
03294XW
Maximum Towing Braked:
3500
kg
ECU Number:
WLE70003
Maximum Towing Unbraked:
750
kg
Tail Harness Length Required:
1200mm
Maximum Static Ball Load:
350
kg
TBM/Lug Part Number:
21366
Wiring Part Number:
WLL90003
FITTING DETAILS:
Towbar Installation Time:
70 mins.
Vehicle Coding Required:
YES
Wiring Installation Time:
30 mins.
RPA Disable/Other:
YES
Total Installation Time:
100 mins
Note:
Bumper Cut Required:
No
•Electric brake wire blue wire taped back to input
harness.
•RPA accessary disable when vehicle is coded.
•Some drilling maybe required (see Step 24).

TOWBAR
INSTALLATION INSTRUCTIONS
PART NUMBER
03294XW
FORD RANGER PX X-BAR
49-75 Pacific Drive Keysborough, VIC 3173
Phone: [phone]
Email: [e-mail]
Rev: BPage 2Issue Date: 13-02-20
ENSURE THAT INSTRUCTIONS ARE UNDERSTOOD PRIOR TO FITMENT.
BEFORE YOU START:
1. Hayman Reese recommends that instructions are read completely prior to fitment.
2. Check all hardware items have been included refer to assembly diagram.
3. Please ensure this towbar is only fitted to vehicle models as per Hayman Reese application guide
(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.
6. 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.
oMeasure from bottom edge along bumper and around corner to the 70 mm point
(Figure 1).
oDo not measure from visible bumper front of corner, upwards (Figure 2).
7. Drilling
•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.
8. 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. Towbar load rating sticker provided with this product shall be conspicuously located on inside rear end of the driver’s door.
b. 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.
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.
Figure 1
INCORRECT
CORRECT
Place Vehicle PCM/ BCM upgrade
warning label in door AND on front
cover of owner’s service handbook
Place Load Rating
sticker inside driver’s
door here
Figure 2

TOWBAR
INSTALLATION INSTRUCTIONS
PART NUMBER
03294XW
FORD RANGER PX X-BAR
49-75 Pacific Drive Keysborough, VIC 3173
Phone: [phone]
Email: [e-mail]
Rev: BPage 3Issue Date: 13-02-20
TOWBAR ASSEMBLY DIAGRAM
ITEM
DESCRIPTION
QTY
ITEM
DESCRIPTION
QTY
1
RANGER/BT50 X-BAR WELDED ASSEMBLY
1
22
SET SCREW HEX FL HD M12x45x1.25P
8
2
RH SIDE ARM
1
23
WASHER FLAT M12x28x3
2
3
WIRING HOUSING
1
24
SET SCREW HEX HD M12x40x1.75P
2
4
PLUG PLATE
1
25
STEP BRACKET SPACER
2
5
XBAR REAR COVER
1
26
BOLT HEX HD M10x40x1.5P
4
6
LH SIDE ARM
1
27
WASHER PLAIN M10x21x1.6
4
7
FORGED SIDE RECOVERY HOOK
2
28
STEP MOUNT SPACER
2
8
FORGED CENTRE RECOVERY HOOK
1
29
SET SCREW HEX HD M12x40x1.75P
10
9
50mm TOWBALL
1
30
WASHER PLAIN 1/2x1-1/8x16
10
10
3.5T FORGED TBM 65MM DROP
1
31
TAPPED PLATE & WIRE
2
11
"D" SHACKLE 10mm
2
32
NUT PLATE LH T6
1
12
ANTI-RATTLE PULL PIN ASSY GOLD
1
33
NUT PLATE RH T6
1
13
BUSH 15ODx8Lx5ID
4
34
SCREW PAN HD M4x16x0.7P
2
14
SCREW PAN HD M5x16x0.8P
4
35
NUT NYLON LOCK HEX M4x0.7P
2
15
NUT NYLON INS LOCK HEX M5x0.8P
4
36
SCREW PAN HD M3x20x0.7P
2
16
XBAR COVER SPRING 60Lx10ODx1P
2
37
NUT NYLON LOCK HEX M3x0.7P
2
17
BOLT COACH M8x20x1.25P
2
38
XBAR LOGO STICKER
2
18
NUT NYLOC M8x1.25P
2
39
ACRYLIC COMPLIANCE LABEL
1
19
SIDE RECOVERY HOOK BOLT KIT
2
40
CAN TRAILER MODULE WARNING LABEL
2
20
CENTRE RECOVERY HOOK BOLT KIT
1
41
WIRING LOOM
1
21
NUT HEX FLANGED M12x1.25P
8

TOWBAR
INSTALLATION INSTRUCTIONS
PART NUMBER
03294XW
FORD RANGER PX X-BAR
49-75 Pacific Drive Keysborough, VIC 3173
Phone: [phone]
Email: [e-mail]
Rev: BPage 4Issue Date: 13-02-20
NOTE: Pre-assembly of X-Bar centre section can assist for vehicles with difficult access.
A.BOLT RECOVERY HOOKS TO TOWBAR
B. MOUNT PLUGS TO BRACKET
AFTER CHOOSING YOUR DESIRED PLUG
CONFIGURATION, INSTALL PLUGS AND WIRING
TO BRACKET USING FASTENERS PROVIDED
TIP: INSERT RECOVERY HOOK BOLTS
THROUGH HOOK AND SPACER TUBES
PRIOR TO FITTING BAR. THIS WILL HELP
LOCATE & GUIDE DURING ASSEMBLY
3 x M12 x 130mm BOLT
CRUSH TUBE
SPACER PLATE
WASHER
NUT
4 x M12 x 45mm BOLT
WASHER
NUT
TORQUE FASTENERS
TO 100 N.m
RAISED SIDE OF
RECOVER HOOK
MUST FACE TOWBAR

TOWBAR
INSTALLATION INSTRUCTIONS
PART NUMBER
03294XW
FORD RANGER PX X-BAR
49-75 Pacific Drive Keysborough, VIC 3173
Phone: [phone]
Email: [e-mail]
Rev: BPage 5Issue Date: 13-02-20
C. INSTALL WIRING HOUSING
D.ATTACH COVER TO HOUSING
4 x M5 BOLT
NYLON BUSH
NYLOC NUT
ROUTE TAIL HARNESS THROUGH EXIT
POINT BEST SUITED TO VEHICLE
USING 2 x M8 COACH BOLTS COMPLETE WITH 1 x
NYLOC NUT PER BOLT, SECURE THE WIRING HOUSING
AND PLUG BRACKET TO THE MAIN TOWBAR
ASSEMBLY THROUGH THE TAB HOLES AS SHOWN.
STEP IV: USE 1 x SPRING
PER SIDE TO ATTACH
HOUSING TO COVER PLATE
TORQUE FASTENERS
TO 22 N.m
NOTE: DO NOT OVERTIGHTEN
FASTENERS TO ENSURE COVER
ASSEMBLY CAN ROTATE FREELY &
TO PREVENT DAMAGE TO BUSHES
STEPS I, II & III
I. INSERT BUSHES INTO SLOTS
II. THEN PLACE COVER OVER HOUSING, LINING UP BUSHES
WITH SCREW HOLES
III. FINALLY FASTEN COVER TO HOUSING BY PUSHING
SCREWS THROUGH BUSHES AND SECURING WITH NUTS

TOWBAR
INSTALLATION INSTRUCTIONS
PART NUMBER
03294XW
FORD RANGER PX X-BAR
49-75 Pacific Drive Keysborough, VIC 3173
Phone: [phone]
Email: [e-mail]
Rev: BPage 6Issue Date: 13-02-20
1. Disconnect the reverse sensor and light
connections.
Lower the spare wheel.
CAUTION: Be aware of wheel dislodgement when
lowering.
2.a FOR VEHICLES WITHOUT FACTORY TOWBAR
i. Remove the 2 x M12 (1) bolts from either
side of the bumper step assembly and
remove the steel bumper from vehicle.
ii. Using towbar sidearm as a guide align the
three existing holes with the holes on the
step bracket.
iii. Using the centre marked, drill a 16mm hole
on the step mount bracket (2).
iv. Apply anti-rust paint to hole.
v. Repeat the step 'ii' to 'v' for RHS.
vi. Release the 2 x lock nuts on the underside of
the bumper on both sides and slide the step
mount bracket outwards to have a gap of
1200mm.
2
3
1

TOWBAR
INSTALLATION INSTRUCTIONS
PART NUMBER
03294XW
FORD RANGER PX X-BAR
49-75 Pacific Drive Keysborough, VIC 3173
Phone: [phone]
Email: [e-mail]
Rev: BPage 7Issue Date: 13-02-20
2.b FOR VEHICLES WITH FACTORY TOWBAR
i. Remove the 2 x M12 factory step bolts (1) from
either side of the bumper step assembly as
shown and remove assembly from vehicle.
ii. Remove towbar.
iii. Remove two bolts (2) from each side of step
connecting the step mount brackets to rear
bumper step assembly and discard the bolts.
iv. Place 10mm spacers (3) in between step mount
brackets and bumper step, then reattach with 2
x M10 bolts per side, complete with 2 x washers
and 1 x nut per bolt.
3. Move Wire Loom located on Diff Housing
Remove wiring loom mounted on the diff housing.
Drill an 8mm hole through the connector bracket
from bottom to top surface which is welded on
the diff housing as shown. Apply anti-rust or paint
to newly drilled hole to prevent corrosion.
Mount the wiring loom on the newly drilled top
hole of the connector bracket.
4. Insert nut plate into chassis rail and align with
holes in chassis.
Repeat for opposite side.
DRILL
DIRECTION
1
2
3

TOWBAR
INSTALLATION INSTRUCTIONS
PART NUMBER
03294XW
FORD RANGER PX X-BAR
49-75 Pacific Drive Keysborough, VIC 3173
Phone: [phone]
Email: [e-mail]
Rev: BPage 8Issue Date: 13-02-20
5. Loosely secure sidearm to underside of chassis
rail via nut plates, with 2 x M12 bolts complete
with 1 x washer per bolt, as shown
Repeat for opposite side.
6. Lift centre welded assembly up to side arms and
loosely secure with 2 x M12 flanged bolts per
side, complete with 1 x flanged nut per bolt, via
bottom 2 holes as shown.
7. If not already done, complete pre-assembly steps
A, B, C, & D now.
8.a FOR VEHICLES WITHOUT FACTORY TOWBAR
i. Loosely secure the step mount bracket of the
rear bumper step assembly to the chassis rail
via towbar sidearm using 3 x M12 bolts
complete with 1 x washer per bolt (1).
NOTE: Use 1 x M12 tapped plate per side for
the hole that doesn't have a captive nut.
ii. Use remaining 2 x M12 flanged bolts per side
complete with 1 x flanged nut to secure
sidearm and step to centre section (2).
NOTE: captive nut hole only used for factory
towbar step variant (3).
1
2
3

TOWBAR
INSTALLATION INSTRUCTIONS
PART NUMBER
03294XW
FORD RANGER PX X-BAR
49-75 Pacific Drive Keysborough, VIC 3173
Phone: [phone]
Email: [e-mail]
Rev: BPage 9Issue Date: 13-02-20
8.b FOR VEHICLES WITH FACTORY TOWBAR
i. See step 8.a.i.
NOTE: Use 1 x M12 tapped plate per side for
the hole that doesn't have a captive nut.
ii. Placing the 10mm spacer plate in between
(1), loosely secure the step mount bracket of
the rear bumper step assembly to the towbar
sidearm using 1 x M12 flanged bolt (2)
complete with 1 x flanged nut and 1 x M12
bolt (3) complete with 1 x washer (to be
secured into captive nut).
iii. Secure sidearm to central assembly with
remaining 1 x M12 flanged bolt per side,
complete with 1 x flanged nut per bolt (4).
9. Torque all bolts as follows:
IMPORTANT: Ensure all bolts are tightened to correct torques using a calibrated torque wrench.
Tighten side arms to chassis rail first in an even pattern/sequence. Repeat for centre section to side arms and
finally torque all other fasteners.
10 x M12 central and side recovery
hook fasteners = 100 N.m
10 x M12 sidearm to chassis
fasteners = 109 N.m
2 x M12 sidearm to centre
section captive nut
fasteners (factory towbar
step ONLY) = 77 N.m
8 x M12 flanged sidearm
to centre section
fasteners = 165 N.m
1
4
3
2

TOWBAR
INSTALLATION INSTRUCTIONS
PART NUMBER
03294XW
FORD RANGER PX X-BAR
49-75 Pacific Drive Keysborough, VIC 3173
Phone: [phone]
Email: [e-mail]
Rev: BPage 10 Issue Date: 13-02-20
IMPORTANT
Due to possible vehicle variations, always confirm any noted
vehicle colour wires with a multi-meter to ensure the correct
function is identified before soldering or scotch locking. For
vehicle wires denoted with two colours (example;
RED/GREEN) the first colour will always be the main wire
colour while the second colour is the thinner trace colour on
the wire.
10. Underneath the front passenger seat, remove the
plastic cover (if applicable).
11. Locate the vehicle CAN, Trailer, Power connectors
(1) from underneath the floor carpet (bracket may
or may not be present).

TOWBAR
INSTALLATION INSTRUCTIONS
PART NUMBER
03294XW
FORD RANGER PX X-BAR
49-75 Pacific Drive Keysborough, VIC 3173
Phone: [phone]
Email: [e-mail]
Rev: BPage 11 Issue Date: 13-02-20
12. Connect the vehicle CAN, Trailer, Power connectors
(1) to the harness patch mating connectors (2).
13. Connect the harness patch connector (3) to the ECU
(4) (WLE70003).
14. Attach the supplied velcro tape to ECU and mount in
a suitable location.
15. On the LHS rear under carriage, locate and
disconnect the blanking connector from the vehicle
16-way connector.
16. Connect the patch harness 16-way connector (1) to
the mating vehicle 16-way connector.
17. Connect the tail harness (1800mm) 8-way connector
(1) to the trailer patch 8-way mating connector (2).
18. Waterproof the trailer patch 8-way connector (1)
and the tail harness 8-way male connector (2) using
silicone or grease (3).

TOWBAR
INSTALLATION INSTRUCTIONS
PART NUMBER
03294XW
FORD RANGER PX X-BAR
49-75 Pacific Drive Keysborough, VIC 3173
Phone: [phone]
Email: [e-mail]
Rev: BPage 12 Issue Date: 13-02-20
19. Route the tail harness (tail length 1800mm) (2) from
the towbar mounting (1), towards the trailer patch
blue connector.
20. Test the trailer wiring harness function using a light board or multi-meter.
21. Secure all harnesses using supplied cable ties (not supplied).
22. Place the fitting instructions in the glove box after fitment.
23. For Comfort and Safety features. To be enable this vehicle must be coded. Once coded the features of MS
System Support OE functionality. Please read the Owner’s Manual for proper operation and understanding.
24. Next step is coding of vehicle. Pay attention to the “Smart Code” instruction (Appendix).

49-75 Pacific Drive Keysborough, VIC 3173
Phone: [phone]
Email: [e-mail]
CUSTOMER INFORMATION
PLACE THESE INSTRUCTIONS IN THE
VEHICLE’S GLOVEBOX AFTER INSTALLATION
Rev: BPage 13 Issue Date: 13-02-20
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 [e-mail].

49-75 Pacific Drive Keysborough, VIC 3173
Phone: [phone]
Email: [e-mail]
CUSTOMER INFORMATION
PLACE THESE INSTRUCTIONS IN THE
VEHICLE’S GLOVEBOX AFTER INSTALLATION
Rev: BPage 14 Issue Date: 13-02-20
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 re-
tighten 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
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)
STEP 2
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)
STEP 3
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.
STEP 4
Tighten Smart Pin Nut by turning nut a further
1/8th of a turn in the clockwise direction using a
24mm spanner (Fig. 4).
STEP 5
Install Smart Pin R-Clip through the hole that
provides best clearance or easiest access. (Fig. 5)
Fig. 1
Fig. 4
(d)
HITCHBOX
(b)
Fig. 5
TRAILER BALL
MOUNT
(a)
(c)
Fig. 3
SMART PIN NUT
(f)
SMART PIN
(e)
Fig. 2
R-CLIP
(g)

Appendix
WARNING: This vehicle requires a system setting to ensure the trailer wiring and control module
are correctly recognised. This process (referred to as ‘coding’) must be carried out to enable
correct vehicle functionality when trailer is connected. Towing features enabled by correct control
module and coding support OE functionality as set by OE manufacturer. Please read the vehicles
owner’s manual for proper operation and understanding.
Coding can be carried out using the Hayman Reese SmartCODE (HRSC) using the following steps.
Note, if HRSC is unavailable, vehicle coding can be carried out by OE manufacturer as needed.
Before you start:
Ensure the HRSC software is up to date using the HAYMAN REESE SMARTCODE PC APP.
Ensure the vehicle battery is fully charged
Use of a battery support unit (BSU) is advised during the coding process.
Ensure towbar, wiring loom and ECU are correctly installed as per Hayman Reese fitting
instructions.
1. Locate the OBD2 port under the drivers footwell on the right-hand side and plug in the HRSC.
2. Close all doors and turn the ignition on
3. Follow the directions on the screen of the HRSC
4. Once the vehicle has been coded successfully proceed to the “clear codes” tab
5. Remove disconnect HRSC from OBD2 port.
6. Check the dash to make sure there are no warning faults.
7. Check the operation of trailer lights and ensure the Reverse Park Assist (RPA) is disabled and
‘trailer on’ icon is active where available.
For technical support and further information on Hayman Reese SmartCODE tool and coding process
contact your nearest Hayman Reese stockist.
Australia: 1800 812 017
New Zealand: 0800 237 886