Hayman Reese 03395RW User manual

TOWBAR
INSTALLATION INSTRUCTIONS
PART NUMBER
03395RW
TOYOTA KLUGER GSU/AXUH CL4 –For vehicle built from 03/2021 - ON
49-75 Pacific Drive Keysborough, VIC 3173
Phone: [phone]
Email: [email protected]
Rev: APage 1Issue Date: 11-08-2021
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.

TOWBAR
INSTALLATION INSTRUCTIONS
PART NUMBER
03395RW
TOYOTA KLUGER GSU/AXUH CL4 –For vehicle built from 03/2021 - ON
49-75 Pacific Drive Keysborough, VIC 3173
Phone: [phone]
Email: [email protected]
Rev: APage 2Issue Date: 11-08-2021
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
03395RW
TOYOTA KLUGER GSU/AXUH CL4 –For vehicle built from 03/2021 - ON
49-75 Pacific Drive Keysborough, VIC 3173
Phone: [phone]
Email: [email protected]
Rev: APage 3Issue Date: 11-08-2021
TOWBAR ASSEMBLY DIAGRAM
ITEM
DESCRIPTION
QTY
ITEM
DESCRIPTION
QTY
1
TOYOTA KLUGER WELDED ASSEMBLY
1
13
NUT HEX HD M12x1.75P
2
2
TRAILER BALL MOUNT
1
14
HITCH BOX COLLAR COVER
1
3
SIDE ARM –LHS
1
15
"D" SHACKLE 10mm
2
4
SIDE ARM –RHS
1
16
SMART PIN GOLD
1
5
LAMINATE PLATE LHS
1
17
TOWBALL 50mm
1
6
SIDE PLATE –RHS
1
18
NUT NYLOC HEX HD M4x0.7P
2
7
SET SCREW HEX HD M12x45x1.25P
16
19
COMPLIANCE LABEL
1
8
WASHER PLAIN M14x28x3
26
20
DOOR RATING LABEL
1
9
NUT HEX HD M12x1.25P
6
21
HAYMAN REESE LOGO STICKER
1
10
EXHAUST SPACER
1
22
PLUG BRACKET
1
11
BOLT HEX HD M8x40x1.25P
2
23
WIRING LOOM
1
12
BOLT HEX HD M12x200x1.75P
2
24
SET SCREW HEX HD M6x16x1.0P
1

TOWBAR
INSTALLATION INSTRUCTIONS
PART NUMBER
03395RW
TOYOTA KLUGER GSU/AXUH CL4 –For vehicle built from 03/2021 - ON
49-75 Pacific Drive Keysborough, VIC 3173
Phone: [phone]
Email: [email protected]
Rev: APage 4Issue Date: 11-08-2021
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.

TOWBAR
INSTALLATION INSTRUCTIONS
PART NUMBER
03395RW
TOYOTA KLUGER GSU/AXUH CL4 –For vehicle built from 03/2021 - ON
49-75 Pacific Drive Keysborough, VIC 3173
Phone: [phone]
Email: [email protected]
Rev: APage 5Issue Date: 11-08-2021
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.

TOWBAR
INSTALLATION INSTRUCTIONS
PART NUMBER
03395RW
TOYOTA KLUGER GSU/AXUH CL4 –For vehicle built from 03/2021 - ON
49-75 Pacific Drive Keysborough, VIC 3173
Phone: [phone]
Email: [email protected]
Rev: APage 6Issue Date: 11-08-2021
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.

TOWBAR
INSTALLATION INSTRUCTIONS
PART NUMBER
03395RW
TOYOTA KLUGER GSU/AXUH CL4 –For vehicle built from 03/2021 - ON
49-75 Pacific Drive Keysborough, VIC 3173
Phone: [phone]
Email: [email protected]
Rev: APage 7Issue Date: 11-08-2021
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

TOWBAR
INSTALLATION INSTRUCTIONS
PART NUMBER
03395RW
TOYOTA KLUGER GSU/AXUH CL4 –For vehicle built from 03/2021 - ON
49-75 Pacific Drive Keysborough, VIC 3173
Phone: [phone]
Email: [email protected]
Rev: APage 8Issue Date: 11-08-2021
13. Place masking tape on the bumper outer skin
Mark and cut out an area as shown to clear the
hitch box.
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.
CL
200mm
35mm
20mm
80mm
60mm
60mm

TOWBAR
INSTALLATION INSTRUCTIONS
PART NUMBER
03395RW
TOYOTA KLUGER GSU/AXUH CL4 –For vehicle built from 03/2021 - ON
49-75 Pacific Drive Keysborough, VIC 3173
Phone: [phone]
Email: [email protected]
Rev: APage 9Issue Date: 11-08-2021
16. On the LHS underside trim,
Mark and cut out an area in the hooking hole
17. On the LHS underside trim,
Mark and cut out an area in the shipping hook
hole to extend 60mm
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.
60mm
150m
m

TOWBAR
INSTALLATION INSTRUCTIONS
PART NUMBER
03395RW
TOYOTA KLUGER GSU/AXUH CL4 –For vehicle built from 03/2021 - ON
49-75 Pacific Drive Keysborough, VIC 3173
Phone: [phone]
Email: [email protected]
Rev: APage 10 Issue Date: 11-08-2021
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.

TOWBAR
INSTALLATION INSTRUCTIONS
PART NUMBER
03395RW
TOYOTA KLUGER GSU/AXUH CL4 –For vehicle built from 03/2021 - ON
49-75 Pacific Drive Keysborough, VIC 3173
Phone: [phone]
Email: [email protected]
Rev: APage 11 Issue Date: 11-08-2021
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.

TOWBAR
INSTALLATION INSTRUCTIONS
PART NUMBER
03395RW
TOYOTA KLUGER GSU/AXUH CL4 –For vehicle built from 03/2021 - ON
49-75 Pacific Drive Keysborough, VIC 3173
Phone: [phone]
Email: [email protected]
Rev: APage 12 Issue Date: 11-08-2021
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.

TOWBAR
INSTALLATION INSTRUCTIONS
PART NUMBER
03395RW
TOYOTA KLUGER GSU/AXUH CL4 –For vehicle built from 03/2021 - ON
49-75 Pacific Drive Keysborough, VIC 3173
Phone: [phone]
Email: [email protected]
Rev: APage 13 Issue Date: 11-08-2021
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: [phone]
Email: [email protected]
CUSTOMER INFORMATION
PLACE THESE INSTRUCTIONS IN THE
VEHICLE’S GLOVEBOX AFTER INSTALLATION
Rev: APage 14 Issue Date: 11-08-2021
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: [email protected]
CUSTOMER INFORMATION
PLACE THESE INSTRUCTIONS IN THE
VEHICLE’S GLOVEBOX AFTER INSTALLATION
Rev: APage 15 Issue Date: 11-08-2021
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)
STEP 6
Install towball onto TBM and tighten to 350 Nm
using a calibrated torque wrench (Fig. 6).
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)
Fig. 6

TOWBAR
INSTALLATION INSTRUCTIONS
PART NUMBER
03395RW
TOYOTA KLUGER GSU/AXUH CL4 –For vehicles built 03/2014 –03/2021
49-75 Pacific Drive Keysborough, VIC 3173
Phone: [phone]
Email: [email protected]
Rev: APage 1Issue Date: 11-08-2021
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

TOWBAR
INSTALLATION INSTRUCTIONS
PART NUMBER
03395RW
TOYOTA KLUGER GSU/AXUH CL4 –For vehicles built 03/2014 –03/2021
49-75 Pacific Drive Keysborough, VIC 3173
Phone: [phone]
Email: [email protected]
Rev: APage 2Issue Date: 11-08-2021
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
03395RW
TOYOTA KLUGER GSU/AXUH CL4 –For vehicles built 03/2014 –03/2021
49-75 Pacific Drive Keysborough, VIC 3173
Phone: [phone]
Email: [email protected]
Rev: APage 3Issue Date: 11-08-2021
TOWBAR ASSEMBLY DIAGRAM
ITEM
DESCRIPTION
QTY
ITEM
DESCRIPTION
QTY
1
TOYOTA KLUGER WELDED ASSEMBLY
1
13
NUT HEX HD M12x1.75P
2
2
TRAILER BALL MOUNT
1
14
HITCH BOX COLLAR COVER
1
3
SIDE ARM –LHS
1
15
"D" SHACKLE 10mm
2
4
SIDE ARM –RHS
1
16
SMART PIN GOLD
1
5
LAMINATE PLATE LHS
1
17
TOWBALL 50mm
1
6
SIDE PLATE –RHS
1
18
NUT NYLOC HEX HD M4x0.7P
2
7
SET SCREW HEX HD M12x45x1.25P
16
19
COMPLIANCE LABEL
1
8
WASHER PLAIN M14x28x3
26
20
DOOR RATING LABEL
1
9
NUT HEX HD M12x1.25P
6
21
HAYMAN REESE LOGO STICKER
1
10
EXHAUST SPACER
1
22
PLUG BRACKET
1
11
BOLT HEX HD M8x40x1.25P
2
23
WIRING LOOM
1
12
BOLT HEX HD M12x200x1.75P
2
24
SET SCREW HEX HD M6x16x1.0P
1

TOWBAR
INSTALLATION INSTRUCTIONS
PART NUMBER
03395RW
TOYOTA KLUGER GSU/AXUH CL4 –For vehicles built 03/2014 –03/2021
49-75 Pacific Drive Keysborough, VIC 3173
Phone: [phone]
Email: [email protected]
Rev: APage 4Issue Date: 11-08-2021
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.

TOWBAR
INSTALLATION INSTRUCTIONS
PART NUMBER
03395RW
TOYOTA KLUGER GSU/AXUH CL4 –For vehicles built 03/2014 –03/2021
49-75 Pacific Drive Keysborough, VIC 3173
Phone: [phone]
Email: [email protected]
Rev: APage 5Issue Date: 11-08-2021
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.