FITTING INSTRUCTIONS FOR
VS WAGON 2100 KG TOW BAR PACKAGE.
V6 & V8 WITH AUTOMATIC TRANSMISSION
Part Number 92053229
NOT INCLUDED IN TOW BAR PACKAGE, BUT MANDATORY TO FIT
PACKAGE - SUPA LIFT SHOCK ABSORBERS
PACKAGE - POWER STEERING FLUID COOLER
PACKAGE - HEAVY DUTY EQUALISER HITCH
TOWING PATCH HARNESS (FLAT 7 PIN), OR
TOWING PATCH HARNESS (ROUND 7 PIN)
HEAVY DUTY RADIATOR (V6 ONLY)
SYNTHETIC REAR AXLE OIL (V6 ONLY)
OIL IDENTIFICATION TAG (V6 ONLY)
92038039
92053149
M40786
92034465
M39838
92057296
HN2040
VS20589
FD810
15JL99
COPYRIGHT
Page 1 of 12
FD810-1a
HOLDEN SERVICE PARTS OPERATIONS
Reproduction in whole or part
prohibited without written approval
Division of HOLDEN Ltd ACN 006 893 232
HSPO2-SH.CDR
M41536
M41535
PACKAGE - AUTO TRANS FLUID COOLER (V6), or
PACKAGE - AUTO TRANS FLUID COOLER (V8)
MANDATORY TO FIT FOR VS SERIES 1 ONLY,
IF EXTERNAL AUTO TRANS FLUID COOLER IS NOT ALREADY FITTED:
2100 KG TOW BAR FITTING INSTRUCTIONS (WAGON)
Disconnect battery negative terminal.
Remove rear bumper bar, refer VS Service Manual Volume 1 Section 1D.
Remove and discard rubber exhaust support rings from rear muffler and allow exhaust to hang down and rest
on panhard bar.
Support fuel tank on jack and remove RHS rear strap retaining bolt and discard spacer. Lower tank 20mm.
NOTE: Ensure tank is supported by jack when strap is removed.
Drill two 19,0mm dia. holes at dimple locations on LHS of the rear compartment floor. Locate upper plate LH
and drill remaining two holes using upper plate LH as a template, refer Figures 1 and 2.
Drill two 17,0mm dia. holes at dimple locations on RHS of rear compartment floor, refer Figures 1 and 2.
Remove deadener from floor panel in areas contacting with upper LHS and RHS plates.
Apply metal primer, Dulux Epoxy Primer Surfacer (DEPS) 410-39790 Black, or equivalent to holes (6 places),
and to any bare metal, allow 10 - 15 minutes to dry.
From inside of rear compartment on LHS of vehicle install four spacers (65 x 17mm). Apply caulking
compound (Dulux Fill and Seal Putty,409-19000), around holes (4 places). Locate LHS upper plate and cup
head bolts (M10 x 100mm) (4 places). Refer Figure 1 and Figure 2 Section C - C.
Install two spacers (51 x 17mm) on RHS of vehicle, apply caulking compound (Dulux Fill and Seal Putty,
(409-19000) around holes (2 places). Locate RHS upper plate and 2 cup head bolts, (M10 x 90mm).
Refer Figure 1 and Figure 2 Section B - B.
Install lower part assembly and retain by installing spring washers and nuts to M10 bolts (6 places) and hand
tighten, refer Figure 1.
Align rear seam plate with welded strip on lower part assembly. Using the rear seam plate as a template, drill
six 9,0mm dia. holes through rear seam, refer Figure 1 and Figure 2 Section D - D.
NOTE: If necessary, remove sealant on seam to ensure an even mounting surface.
Ensure surfaces to be coated are free from contaminents, oil and dirt. Apply metal primer, Dulux Epoxy
Primer Surfacer (DEPS) 410-39790 Black, or equivalent and allow 10 - 15 minutes to dry, then caulking
compound, Dulux Fill and Seal Putty, 409-19000 to any bare metal and around holes, (6 places).
Refer Figure 1 and Figure 2 Section D - D.
Attach rear seam plate using M8 bolts, flat washers, spring washers and nuts (6 places), hand tighten. Refer
Figure 1 and Figure 2 Section D - D.
Attach bracing strap to lower part assembly using M10 x 30mm bolts and washers (2 places), refer Figure 1.
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
FD810
15JL99
COPYRIGHT
Page 2 of 12
FD810-2a
HOLDEN SERVICE PARTS OPERATIONS
Reproduction in whole or part
prohibited without written approval
Division of HOLDEN Ltd ACN 006 893 232
HSPO2-SH.CDR
11
11
33
33
22
22
22
44
44
70 - 90Nm
17 - 22Nm
40 - 55Nm
15 - 25Nm
LOWER PART ASSEMBLY
BOLT CUP HEAD
M10 x 90
(2 PLACES)
BOLT CUP HEAD
M10 x 100
(4 PLACES)
BOLT CUP HEAD
M10 x 90
(2 PLACES)
PLATE
(2 PLACES)
PLATE
PLATE
SPACER
(2 PLACES)
SPACER
(4 PLACES)
SPACER
(2 PLACES)
DRILL 17,0 DIA.
DRILL 10,0 DIA.
+0,5
0,0
+0,5
0,0
8 HOLES
6 HOLES
WASHER M10
(8 PLACES)
WASHER M10
(2 PLACES)
WASHER M8
(6 PLACES)
NUT M10
(8 PLACES)
BOLT M10
(2 PLACES)
NUT M8
(6 PLACES)
BRACING
STRAP
ENSURE SURFACES TO BE COATED ARE FREE FROM CONTAMINENTS,
OIL AND DIRT. APPLY METAL PRIMER, DULUX EPOXY PRIMER SURFACER
(DEPS) 410-39790 BLACK, OR EQUIVALENT AND ALLOW 10 - 15 MINUTES
TO DRY, THEN CAULKING COMPOUND, DULUX FILL AND SEAL PUTTY,
409-19000 TO ANY BARE METAL AND AROUND HOLES, (14 PLACES).
FUEL TANK STRAP
& ATTACHING
HARDWARE
REAR SEAM
PLATE
TOW BAR TONGUE
'D' SHACKLE
(2 PLACES)
NUT M16
BOLT M8 x 20
(6 PLACES)
ANTI-RATTLE
BOLT ASM M10
BOLT M16
PART OF TOW BAR TONGUE PACKAGE
FD810
15JL99 Figure 1
COPYRIGHT
Page 3 of 12
FD810-3a
HOLDEN SERVICE PARTS OPERATIONS
Reproduction in whole or part
prohibited without written approval
Division of HOLDEN Ltd ACN 006 893 232
HSPO2-SH.CDR
Align mounting bracket (angle section) of bracing strap on panhard mounting body crossmember. Ensure
brace is aligned along centre line of vehicle and fits evenly along crossmember. Mark bolt hole locations.
NOTE: Ensure holes will be drilled through between ribs in rear compartment floor to enable correct
alignment of plates. Refer to Figure 2 Section A-A.
Install bracing strap and drill two 17,0mm dia. holes at marked locations. Apply metal primer, Dulux
Epoxy Primer Surfacer (DEPS) 410-39790 Black to holes and allow 10 - 15 minutes drying time.
Install bracing strap using M10 x 30mm bolts and washers (2 places). Hand tighten.
From inside rear compartment, install spacers into holes.
NOTE: Longer spacer to be installed in LH hole.
Apply caulking compound (Dulux Fill and Seal Putty 409-19000) around holes
(2 places). Refer Figure 2 and Figure 3 Section A-A.
Install plates (2 places) over holes and locate with M10 x 90mm cup head bolts (2 places).
Retain by installing spring washers and nuts to M10 bolts (2 places). Hand tighten.
Tighten all M10 bolts and nuts to correct torque specification (10 off).
M10 BOLT AND NUT TORQUE SPECIFICATION 40 - 55Nm
Tighten all M8 bolts and nuts to correct torque specification (6 off).
M8 BOLT AND NUT TORQUE SPECIFICATION 17 - 22Nm
Install fuel tank strap and retaining bolt to correct torque specification.
FUEL TANK STRAP RETAINING BOLT TORQUE SPECIFICATION 15 - 25Nm
Mark and cut rear bumper, refer to allow reinstallation of rear bumper bar, refer Figure 3.
Reinstall rear bumper, refer VS Service Manual Volume 1 Section 1D.
Install tow bar tongue into tow bar assembly, install tow bar tongue retaining bolt and nut. Install tow bar
tongue anti-rattle bolt (M10 x 35mm) and nut and tighten to correct torque specifications.
TOW BAR TONGUE RETAINING BOLT AND NUT TORQUE SPECIFICATION 80 - 90Nm
TOW BAR ANTI-RATTLE BOLT AND NUT TORQUE SPECIFICATION 15 - 25Nm
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
FD810
15JL99
COPYRIGHT
Page 4 of 12
FD810-4a
HOLDEN SERVICE PARTS OPERATIONS
Reproduction in whole or part
prohibited without written approval
Division of HOLDEN Ltd ACN 006 893 232
HSPO2-SH.CDR
A-A
SECTION B-B
SECTION
D-D
SECTION
C-C
SECTION
NOTE: REMOVE BUMPER FACIA
TO FACILITATE TOW BAR
FITMENT
FLOOR PAN
SPARE WHEEL
WELL
FLOOR PAN
17,0 DIA. HOLE
(REF.)
17,0 DIA. HOLE
(REF.)
FLOOR PAN
17,0 DIA. HOLE
(REF.)
SPARE WHEEL
WELL
SPARE WHEEL WELL
REAR VALANCE
CLEAN SEALANT
FROM THIS AREA
PRIOR TO ASSEMBLY
10,0 DIA. HOLE
(REF.)
92053229
2100 kg WAGON
TOW BAR ASSEMBLY
D
D
B
B
C
C
A
A
ENSURE SURFACES TO BE COATED ARE FREE FROM CONTAMINENTS,
OIL AND DIRT. APPLY METAL PRIMER, DULUX EPOXY PRIMER SURFACER,
410-39790 BLACK, OR EQUIVALENT AND ALLOW 10 - 15 MINUTES TO DRY,
THEN CAULKING COMPOUND, DULUX FILL AND SEAL PUTTY, 409-19000
TO ANY BARE METAL AND AROUND HOLES,(14 PLACES).
FD810
15JL99 Figure 2
COPYRIGHT
Page 5 of 12
FD810-5a
HOLDEN SERVICE PARTS OPERATIONS
Reproduction in whole or part
prohibited without written approval
Division of HOLDEN Ltd ACN 006 893 232
HSPO2-SH.CDR
REAR AXLE LUBRICANT CHANGE (V6 ONLY)
Due to high differential loads when towing 2100kg, it is essential that a synthetic (High Performance)
differential oil is used.
All V8 Commodores, and V6 Commodores with Limited Slip Differential (LSD) and or Anti Lock Braking
System (ABS), are supplied standard with synthetic oil. Differentials filled with synthetic oil may be easily
identified via a metal tag stating "HIGH PERFORMANCE, USE APPROVED LUBRICANT ONLY". Refer
Figure 3.
For differentials not identified with this tag, a mineral based oil has been used. Before undertaking 2100kg
towing it is essential that the oil be changed to synthetic differential oil, Mobillube SHC, SAE 80W-140 (ID)
product code 51107 or equivalent to Holden's specification number HN2040. Refer to Owner's Manual
Volume No. 2 Section 4B1 for correct oil change procedure.
NOTE: Lowest retaining bolt on rear axle housing cover may be used for draining of oil.
Ensure that after the oil has been replaced, the axle is identified with the correct "HIGH PERFORMANCE,
USE APPROVED LUBRICANT ONLY" tag: P/No. VS20589. This will prevent incorrect oil being used
during service operations.
1.
2.
3.
4.
FD810
15JL99
COPYRIGHT
Page 6 of 12
FD810-6a
HOLDEN SERVICE PARTS OPERATIONS
Reproduction in whole or part
prohibited without written approval
Division of HOLDEN Ltd ACN 006 893 232
HSPO2-SH.CDR
REAR BUMPER BAR
REMOVE NOTCHED AREA
HIGH
PERFORMANCE
USE APPROVED
LUBRICANT ONLY
BROADCAST CODE
FILLER PLUG
OIL IDENTIFICATION
TAG
VS20589
REAR AXLE
HOUSING
COVER
NOTE: WHERE OIL IDENTIFICATION TAG IS NOT FITTED,
DIFFERENTIAL OIL MUST BE CHANGED TO
SYNTHETIC DIFFERENTIAL OIL, MOBILLUBE SHC,
SAE 80W - 140 (ID) PRODUCT CODE 51107 OR
EQUIVALENT TO HN2040, THEN ATTACH OIL
IDENTIFICATION TAG VS20589.
FD810
15JL99 Figure 3
COPYRIGHT
Page 7 of 12
FD810-7a
HOLDEN SERVICE PARTS OPERATIONS
Reproduction in whole or part
prohibited without written approval
Division of HOLDEN Ltd ACN 006 893 232
HSPO2-SH.CDR
CENTRE BEARING HEAT SHIELD
Loosen centre bearing carrier to underbody retaining bolts, DO NOT REMOVE BOLTS.
Select correct heat shield: V6 - 92053241, or V8 - 92047132 (discard shield which is not required)
Slide centre bearing heat shield on top of centre bearing carrier and tighten to correct torque specification,
refer Figure 4 view B.
CENTRE BEARING TO LOWER CUP GUIDE
RETAINING BOLT TORQUE SPECIFICATION 20 - 25Nm
1.
2.
3.
HEAT SHIELD INTERMEDIATE MUFFLER
Disconnect intermediate exhaust pipe from catalytic converter and allow exhaust to hang on mounts, refer
VS Service Manual Volume 4 Section 8B1.
WARNING: BEFORE REMOVAL OF PROPELLER SHAFT, PAINT A MARK ON THE PROPELLER
SHAFT AND PINION FLANGE SO THAT THEY CAN BE LINED UP ON REASSEMBLY.
Remove propeller shaft from vehicle, refer VS Service Manual Volume 2 Section 4C.
Position heat shield centrally over pressed holes in crossmember assembly rear, refer Figure 4 view C.
Using shield as template mark the seven retaining hole centres and drill 4,0mm holes in floor pan where
marked.
Secure the heat shield to floor pan using SP3878 rivets (7 places).
Install propeller shaft, refer VS Service Manual Volume 2 Section 4C.
Reconnect intermediate exhaust pipe to catalytic converter and tighten to correct torque specification, refer
VS Service Manual Volume 4 Section 8B1.
INTERMEDIATE EXHAUST PIPE TO CATALYTIC CONVERTER
ATTACHING BOLT TORQUE SPECIFICATION 30 - 50 Nm.
NOTE: Do not install rear muffler hangers until completion of rear muffler heat shield installation below.
Remove and discard rear muffler support rings.
Install silicone support rings to rear muffler (2 places), refer Figure 4 View D.
1.
2.
3.
4.
5.
6.
When installing supa lift shock absorbers, discard rubber top mounts supplied with supa lift kit and install
yellow polyurethane heavy duty insulators provided in towing package, refer Figure 4 View A.
1.
1.
2.
REAR MUFFLER SILICONE EXHAUST SUPPORT RINGS.
FD810
15JL99
COPYRIGHT
Page 8 of 12
FD810-8a
HOLDEN SERVICE PARTS OPERATIONS
Reproduction in whole or part
prohibited without written approval
Division of HOLDEN Ltd ACN 006 893 232
HSPO2-SH.CDR
DRILL 4,0 DIA.
(7 HOLES)
M40803
SUPA LIFT
INSULATORS
TOP MOUNTS
(2 PLACES)
FRONT
OF
VEHICLE
SHIELD-
INTERMEDIATE
MUFFLER
92047134
POP RIVET
SP3878
(7 PLACES)
TO LOCATE SHIELD.
POSITION CENTRALLY
OVER FLANGED HOLES
IN REAR CROSSMEMBER
ASSEMBLY
REPLACE EXISTING
EXHAUST SUPPORT
RINGS WITH
SILICONE EXHAUST
SUPPORT RINGS
92049407
(2 PLACES)
A
VIEW
D
VIEW
C
VIEW
B
VIEW
11
22
20 - 25Nm
20 - 35Nm
LOOSEN CENTRE BEARING
CARRIER BOLTS. RETIGHTEN
AFTER INSTALLATION OF
HEAT SHIELD
FRONT OF
VEHICLE
NUT - EXISTING
(2 PLACES)
SPACER - EXISTING
(2 PLACES)
BOLT - EXISTING
(2 PLACES)
HEAT SHIELD -
CENTRE BEARING
92053241 (V6)
92047132 (V8)
11
22
C
B
A
D
FD810
15JL99 Figure 4
COPYRIGHT
Page 9 of 12
FD810-9a
HOLDEN SERVICE PARTS OPERATIONS
Reproduction in whole or part
prohibited without written approval
Division of HOLDEN Ltd ACN 006 893 232
HSPO2-SH.CDR
Remove backing from Owner's Manual sticker.
Place sticker on front cover of Owner's Manual.
Open bonnet.
Remove backing from Tyre Placard sticker.
Place sticker in vacant area on original Tyre Placard.
NOTE: Do not cover any information on the original Tyre Placard.
Raise the front of vehicle, refer VS Service Manual Volume 1 Section 0A.
Remove front wheels, refer VS Service Manual Volume 5 Section 10.
NOTE : I nspect front and rear pads to ensure the same brake pad material is fitted front
and rear. Friction material markings are visible with wheels removed and calipers
still fitted to vehicle. The following materials may be used with this towing package
(in order of preference) :
If front brake pads differ from rear brake pads, replace whichever is least
preferred (refer chart) to match other pad type.
Remove front brake calipers, refer VS Service Manual Volume 2 Section 5A.
Remove front hub/brake discs, refer VS Service Manual Volume 2 Section 5A.
Remove front brake shields and discard, refer VS Service Manual Volume 12 Section 3.
Reinstall front hub/brake discs, refer VS Service Manual Volume 2 Section 5A.
Reinstall front calipers, refer VS Service Manual Volume 2 Section 5A.
Reinstall front wheels, refer VS Service Manual Volume 5 Section 10, and lower vehicle.
Reconnect battery negative terminal.
Most
Preferred
1.
2.
3.
1.
2.
3.
4.
5.
6.
7.
8.
9.
OWNER'S MANUAL STICKER
1.
2.
TYRE PLACARD STICKER
FRONT BRAKE SHIELD REMOVAL AND PAD INSPECTION
PLACE TYRE PLACARD
STICKER (M40752),
IN VACANT AREA ON
EXISTING TYRE
PLACARD STICKER.
Pad
Marking
Part No.
Front
Part No.
Rear
BM962 92055692 92055693
BMT6100 VS19504 VS19505
BM826 92046580 92046581
FD810
15JL99
COPYRIGHT
Page 10 of 12
FD810-10a
HOLDEN SERVICE PARTS OPERATIONS
Reproduction in whole or part
prohibited without written approval
Division of HOLDEN Ltd ACN 006 893 232
HSPO2-SH.CDR
Install supa lift shock absorbers in accordance with the fitting instructions contained in supa lift
shock absorber package.
Install automatic transmission cooler in accordance with the fitting instructions contained in
automatic transmission cooler package.
Install power steering cooler in accordance with the fitting instructions contained in the power
steering cooler package.
Install rear heavy duty equaliser hitch in accordance with the fitting instructions contained in the
heavy duty equaliser hitch package.
Install towing patch harness in accordance with the fitting instructions contained in towing patch
harness package.
Install heavy duty radiator in accordance with procedure outlined in VS Service Manual, Volume 1,
Section 6B1 (V6 only).
NOT PART OF TOW BAR PACKAGE, BUT MANDATORY TO FIT *
SUPA LIFT SHOCK ABSORBERS *
AUTOMATIC TRANSMISSION COOLER *
(FOR VS SERIES 1 ONLY, IF AUTO TRANS FLUID COOLER IS NOT ALREADY FITTED)
SUPA LIFT SHOCK ABSORBER PACKAGE
AUTOMATIC TRANSMISSION OIL COOLER PACKAGE (V6)
or
AUTOMATIC TRANSMISSION OIL COOLER PACKAGE (V8)
92038039
M41536
M41535
POWER STEERING COOLER *
HEAVY DUTY EQUALISER HITCH *
TOWING PATCH HARNESS *
HEAVY DUTY RADIATOR * (V6 ONLY)
POWER STEERING COOLER PACKAGE
HEAVY DUTY EQUALISER HITCH PACKAGE
TOWING PATCH HARNESS (FLAT 7 PIN)
TOWING PATCH HARNESS (ROUND 7 PIN)
HEAVY DUTY RADIATOR PACKAGE
or
92053149
M40786
92034465
M39838
92057296
FD810
15JL99
COPYRIGHT
Page 11 of 12
FD810-11a
HOLDEN SERVICE PARTS OPERATIONS
Reproduction in whole or part
prohibited without written approval
Division of HOLDEN Ltd ACN 006 893 232
HSPO2-SH.CDR
PACKAGE - SUPA LIFT SHOCK ABSORBERS
PACKAGE - POWER STEERING FLUID COOLER
PACKAGE - HEAVY DUTY EQUALISER HITCH
TOWING PATCH HARNESS (FLAT 7 PIN) or
TOWING PATCH HARNESS (ROUND 7 PIN)
HEAVY DUTY RADIATOR (V6 ONLY)
OIL IDENTIFICATION TAG (V6 ONLY)
SYNTHETIC REAR AXLE OIL, EG. MOBILLUBE SHC, SAE 80W - 140,
OR EQUIVALENT LUBRICANT TO HOLDEN'S SPECIFICATION HN2040 (V6 ONLY).
NOT INCLUDED IN TOW BAR PACKAGE, BUT MANDATORY TO FIT :
92038039
92053149
M40786
92034465
M39838
92057296
VS20589
HN2040
2100 KG TOW BAR PACKAGE FOR WAGON (92053229)
PARTS LIST
PART NO. DESCRIPTION QUANTITY
TOW BAR ASSEMBLY
CONSISTS OF:
LOWER PART ASSEMBLY
PLATE - LHS LOWER PART ASSEMBLY TO LOAD FLOOR
SPACER - LHS LOWER PART ASSEMBLY TO LOAD FLOOR
BOLT - M10 x 100mm CUP HEAD
NUT - M10
SPRING WASHER - 10mm
SPACER - RHS LOWER PART ASSEMBLY TO LOAD FLOOR
BOLT - M10 x 90mm CUP HEAD
NUT - M10
SPRING WASHER - 10mm
REAR SEAM PLATE
BOLT - M8 x 20mm HEX HEAD
NUT - M8
FLAT WASHER - 8mm
SPRING WASHER - 10mm
BRACING STRAP
BOLT - M10 x 30mm HEX HEAD
SPRING WASHER - 10mm
SPACER - LHS BRACING STRAP TO LOAD FLOOR
SPACER - RHS BRACING STRAP TO LOAD FLOOR
BOLT - M10 x 90mm CUP HEAD
NUT - M10
SPRING WASHER -10mm
TOW BAR TONGUE PACKAGE (CHROME)
CONSISTS OF:-
TOW BAR TONGUE
BOLT - M16 x 85mm
NUT - M16 (NYLOC)
BOLT M10 x 35mm
NUT - M10
'D' SHACKLE
RIVET - BLIND 4,0 x 13,2mm
SILICONE EXHAUST RING
INSULATOR - SUPA LIFT TOP MOUNTS
BOOKLET FITTING INSTRUCTIONS
CHART - 2100KG TOWING SYSTEMS
STICKER - TYRE PLACARD
STICKER - OWNER'S HANDBOOK
HEAT SHIELD - INTERMEDIATE MUFFLER
HEAT SHIELD - CENTRE BEARING(V6/V8, DISCARD SHIELD
WHICH IS NOT REQUIRED).
SP3878
92049407
M40803
FD810
FD825
M40742
M40741
92053240
92053241/92047132
1
1
1
1
4
4
4
1
2
2
2
1
6
6
6
6
1
2
2
1
1
2
2
2
1
1
1
1
1
1
2
7
2
2
1
1
1
1
1
1/1
92048784
M40964
FD810
15JL99
COPYRIGHT
Page 12 of 12
FD810-12a
HOLDEN SERVICE PARTS OPERATIONS
Reproduction in whole or part
prohibited without written approval
Division of HOLDEN Ltd ACN 006 893 232
HSPO2-SH.CDR
MANDATORY TO FIT FOR SERIES 1 ONLY,
IF EXTERNAL AUTO TRANS FLUID COOLER IS NOT ALREADY FITTED :
M41536
M41535
PACKAGE - AUTO TRANS FLUID COOLER (V6) or
PACKAGE - AUTO TRANS FLUID COOLER (V8)