Hayman Reese 03408RW User manual

TOWBAR
INSTALLATION INSTRUCTIONS
PART NUMBER
03408RW
FORD RANGER CL4 UTE MY22
49-75 Pacific Drive Keysborough, VIC 3173
Phone: [phone]
Email: [e-mail]
Rev: APage 1Issue Date: 29-07-2022
PRODUCT DETAILS:
Part Number:
03408RW
Maximum Towing Braked:
3500
kg
ECU Number:
WLE70029
Maximum Towing Unbraked:
750
kg
Tail Harness Length Required:
1200mm
Maximum Static Ball Load:
350
kg
TBM/Lug Part Number:
21161
Wiring Part Number:
WLL90029
FITTING DETAILS:
Towbar Installation Time:
60 Mins.
Hayman Reese SmartCODE Solution Required:
YES
Wiring Installation Time:
30 Mins.
RPA Disable/Other:
YES
Total Installation Time:
90 Mins.
Bumper Cut Required:
Yes
Note:
•Please refer vehicles owner’s manual for proper
operation and understanding of towing features
enabled when coded.

TOWBAR
INSTALLATION INSTRUCTIONS
PART NUMBER
03408RW
FORD RANGER CL4 UTE MY22
49-75 Pacific Drive Keysborough, VIC 3173
Phone: [phone]
Email: [e-mail]
Rev: APage 2Issue Date: 29-07-2022
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
03408RW
FORD RANGER CL4 UTE MY22
49-75 Pacific Drive Keysborough, VIC 3173
Phone: [phone]
Email: [e-mail]
Rev: APage 3Issue Date: 29-07-2022
TOWBAR ASSEMBLY DIAGRAM
ITEM
DESCRIPTION
QTY
ITEM
DESCRIPTION
QTY
1
FORD RANGER WELDED ASSEMBLY
1
14
TRAILER BALL MOUNT
1
2
STEP WELDED ASSEMBLY
1
15
BOLT HEX HD M12x35x1.75P
2
3
LARGE UNIVERSAL PLUG BRKT KIT
1
16
WASHER PLAIN 1/2"
2
4
WASHER PLAIN M14x28x3.0
8
17
SMART PIN GOLD
1
5
BOLT HEX HD M14x130x2.0P
8
18
10mm "D" SHACKLE
2
6
BRACKET - STEP
2
19
HAYMAN REESE LOGO STICKER
1
7
PLUG BRACKET 2
1
20
HITCH BOX COLLAR COVER
1
8
BOLT HEX HD M8x35x1.25P
4
21
TOWBALL 50mm
1
9
NUT HEX HD M8x1.25P
4
22
COMPLIANCE LABEL
1
10
WASHER PLAIN M8x22x3
8
23
LOAD RATING LABEL
1
11
NUT NYLOC INS HEX HD M5x0.8P
2
24
CAN MODULE WARNING LABEL
2
12
WASHER PLAIN M5x10x1
2
25
WIRING LOOM
1
13
SCREW PAN XR M5x16x0.8P
2

TOWBAR
INSTALLATION INSTRUCTIONS
PART NUMBER
03408RW
FORD RANGER CL4 UTE MY22
49-75 Pacific Drive Keysborough, VIC 3173
Phone: [phone]
Email: [e-mail]
Rev: APage 4Issue Date: 29-07-2022
1. On the LHS of the chassis, locate the vehicle rear
step 16-way wiring connector and disconnect.
2. On the RHS of the under carriage remove the
following fasteners:
2x M8
1x M10
Repeat for the other side.
Remove rear step and store in a safe place.
3. Remove 4x M14 bolts that secure the rear step
support bracket and discard both bracket and
fasteners.

TOWBAR
INSTALLATION INSTRUCTIONS
PART NUMBER
03408RW
FORD RANGER CL4 UTE MY22
49-75 Pacific Drive Keysborough, VIC 3173
Phone: [phone]
Email: [e-mail]
Rev: APage 5Issue Date: 29-07-2022
4. Loosley assemble the components to the towbar as
shown, using fasteners identified on Page 3.
5. Place the tow bar to chassis and loosely secure with
4x M14 bolts and 4x washer.
Repeat for the other side
6. Determine the centre light of the garnish, mask of as
per image mark a line 20mm down from the feature
line.
7. Cut out a section 85mm wide.
20mm
85mm

TOWBAR
INSTALLATION INSTRUCTIONS
PART NUMBER
03408RW
FORD RANGER CL4 UTE MY22
49-75 Pacific Drive Keysborough, VIC 3173
Phone: [phone]
Email: [e-mail]
Rev: APage 6Issue Date: 29-07-2022
8. Refit the rear step to vehicle align and secure the
step brackets M8 and M12 bolts.
9. Reconnect the rear step connector.
Torque fasteners as follows:
M14 x 2.0P = 170 Nm
M12 x 1.75P = 109 Nm
M8 x 1.25P = 22Nm
10. On the LHS under carriage, locate and disconnect
the blanking connector from the 16-way trailer
output Pre-Wire connector.
11. Connect the trailer patch (WLL90029) to the vehicle
mating connector.
12. Mount the trailer plug to plug bracket, route the tail
blue connector towards trailer patch mating
connector.
13. Connect and waterproof the blue connector using
electrical grease or silicon.

TOWBAR
INSTALLATION INSTRUCTIONS
PART NUMBER
03408RW
FORD RANGER CL4 UTE MY22
49-75 Pacific Drive Keysborough, VIC 3173
Phone: [phone]
Email: [e-mail]
Rev: APage 7Issue Date: 29-07-2022
14. From inside the LHS of vehicle remove the
following interior trims.
•Dislodge the door seal.
•Remove and detach the glove box. (When open
pull in the side stoppers).
•Remove the end dash trim.
•Remove the fastener that’s secures the front
fascia trim, unclip the trim.
15. Remove the Gateway module 3x fasteners.
16. Move the module enough to gain access the trailer
Pre-wire connectors.
Note: Care must be taken when moving the
module.
17. Using a flat blade screwdriver release the connector
tabs for the 3x trailer pre-wire connectors.

TOWBAR
INSTALLATION INSTRUCTIONS
PART NUMBER
03408RW
FORD RANGER CL4 UTE MY22
49-75 Pacific Drive Keysborough, VIC 3173
Phone: [phone]
Email: [e-mail]
Rev: APage 8Issue Date: 29-07-2022
18. From underneath the LHS footwell pull down the
released connectors.
19. Connect the trailer patch (WLL90029) interior
harness to mating connectors.
20. Connect the trailer patch connector to the ECU
(WLE70029).
21. Remove the ECU adhesive backing tape and secure
the module in behind the LHS footwell.

TOWBAR
INSTALLATION INSTRUCTIONS
PART NUMBER
03408RW
FORD RANGER CL4 UTE MY22
49-75 Pacific Drive Keysborough, VIC 3173
Phone: [phone]
Email: [e-mail]
Rev: APage 9Issue Date: 29-07-2022
22. Refit all removed parts from steps 14- 16 in
reverse.
23. Test the functionality of trailer module ensuring all
lights work using a trailer test board.
24. Next step is coding of vehicle.
25. Pay attention to the “SmartCODE” instruction
page.
26. Once vehicle is coded test trailer functionality with
a test board.
Place fitting instructions in glovebox when finished.

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: APage 10 Issue Date: 29-07-2022
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: APage 11 Issue Date: 29-07-2022
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

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