Dennis' VW Service



Dennis' VW Service

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"The Vanagon Man"

Dennis Haynes Telephone 631-563-8248

CELL 631-897-0345

E-mail Dhaynes@

970 Smithtown Ave.

Bohemia NY. 11716

Installation instructions for your Vanagon Class Three "Style" Trailer Hitch

Notice: This trailer hitch was designed to allow the mounting of many accessories such as bicycle racks and luggage carriers to the rear of your Vanagon. It was not designed nor intended to be used for towing anything in excess of the Vehicle Manufacturers recommendations. For most Vanagons, this is 2000 pounds with a maximum tongue weight of 150 pounds. This hitch must never be used with a "Weight Distributing" type of coupling. Both the hitch and the vehicle can be damaged with disastrous results. In addition, most states require that any towed load in excess of 1000 pounds be equipped with its own braking system. Your vehicle will handle differently with a trailer in tow or with a load mounted on the hitch. The weight capacity that the vehicle can carry must be reduced by an amount equal to the tongue weight on the hitch. For loads that are mounted and extended off the hitch, the weight of that load should be doubled, and then subtracted from the vehicle capacity. The Vanagon is not designed to be used as a "Tow" vehicle. The Engine, Transmission, and Brakes are excessively stressed when used for this purpose. Drive accordingly.

This hitch was also designed to be easy to install. The installation requires no holes to be drilled on the vehicle. The only cutting that needs to be done is for the side brackets to extend below the bumper. This can be done with a hacksaw, although I prefer to use a jigsaw or cut-off wheel. The hitch is supplied with new hardware. The mounting bolts that attach the unit to the frame are Grade 12.9; the bumper mounting bolts are grade 10.9 or stainless steel. These are high strength fasteners that are plated to resist rust and corrosion. It is highly recommended that either an Anti-Seize or Lock-tight are used on the bolt threads to allow for future disassembly. Note that the 12mm bolts used to mount the hitch on the van are not the same thread pitch of as the originals. They are not interchangeable. The hitch will not need to be removed for any normal servicing of the vehicle.

Tools Needed:

• Open end and socket wrenches, 12, 13, 18, 19 millimeters.

• #2 Philips screwdriver.

• Small straight blade screwdriver.

• Needle nose pliers, (to remove rubber impact strip).

• Cutting tools to cut slots in bumper. Your choice.

Installation Procedure:

All Vanagons with metal bumpers.

(See next page for the “Aero” Style Bumpers)

• Remove original bumper and brackets. It is usually easiest to remove the bumper and brackets as an assembly. Especially if you have the rubber impact strip mounted across the bumper. Remove the sheet metal screws that hold the bumper end caps to the body. Each cap has a plug that needs to be removed to access the screw. Use a small screwdriver to remove the plug, and then carefully remove the screw. This screw is usually rusted, (so is the sheet metal). Do not remove the end caps from the bumper itself. Next, remove the bolts that hold the bumper brackets to the frame. There are two 12mm bolts on each side. Use the 19mm wrench. Then slide entire bumper assembly off vehicle.

• Remove rubber impact strip if equipped. Using the pliers carefully squeeze the plastic mounting clips and gently push them through the bumper. Be careful not to damage the clips or the impact strip. If time permits, it may be a good idea to purchase a set of these clips from the dealer in advance. There is nothing more unsightly than a Vanagon with stuff falling off it. After the strip is removed, remove the brackets from the bumper and put them in storage with their original hardware.

• Mount new hitch assembly on van. Depending on condition of van, this is a good time to put some rust preventative paint coating or wax inside the frame boxes. Slide side pieces into frame pockets. Coat the 12mm bolts with either Anti-Seize or Blue Lock-tite, (preferred), then install the bolts and washers through the frame and into the hitch. The wavy washers go between the bolt head and the flat washer. It will take some work to get all six bolts lined up and started. Use hand wrench (18 or 19mm) to start the threads. Do not tighten until all six bolts are started. You do not want to strip the welded nuts. Tighten all bolts securely!

• Cut notches in rear bumper. Hold bumper up to hitch brackets. The brackets should be about 3/8 inch to the outside of the bottom bumper mounting holes. Mark where the slots need to be cut. Give some extra room on each side. I usually cut a 1/2 inch wide slot. The slot needs to be cut half way into the bottom corner of the bumper. After cutting the slot, test fit the bumper to the brackets. Trim as needed. There should be no interference between the back of the brackets and the inside of the bumper. This is important, so that the bumper will sit level. Apply some paint or rust proofing material to the cut edges to prevent them from rusting.

• Mount bumper and trim. Using the new 8mm bolts, mount the bumper to the brackets. Use Anti-Seize here as these bumpers seem to need replacing often, (It's really a trim piece, not a bumper). Re-attach the end caps to the body. If the sheet metal screws and the body are too rusty for the screws to hold, replace with #10 stove bolts, nuts, and washers. More Anti-Seize, undercoating, wax, or something. Re-install the plugs and the rear impact strip.

• Go show off your new hitch! You are now finished!

Installation Procedure:

All Vanagons with Aero or Plastic Bumpers.

• Remove original bumper and brackets. The bumper and brackets have to be removed as a complete assembly. Remove the bolts that hold the bumper brackets to the frame, (two 12mm bolts on each side, 19mm wrench) and the screws that hold the side trim pieces to the body. Then slide entire bumper assembly off vehicle.

• Remove brackets from bumper. Carefully unbolt the original brackets from the bumper. Often the top bolt is seized into the pressed in inserts. Avoid destroying these inserts. Use lots of “Rust Bust” as needed.

• Cut notches in rear bumper. Hold bumper up to the hitch assembly. The brackets should be about 3/8 inch to the outside of the bottom bumper mounting holes. Mark where the slots need to be cut. Give some extra room on each side. I usually cut a 1/2 inch wide slot. The slot needs to be cut half way into the bottom corner of the bumper. After cutting the slot, test fit the bumper to the hitch brackets. Trim as needed. There should be no interference between the back of the brackets and the inside of the bumper. This is important, so that the bumper will sit level.

• Mount bumper to hitch. Using the new 8mm bolts, mount the bumper to the brackets. Use Anti-Seize here, especially in the top bolts that thread into those inserts. Since these bumpers seem to need replacing often, (It's really a trim piece, not a bumper), pay careful attention to proper fit. The brackets may have to slightly bent and washers may need to be added so that bumper fits properly on hitch. Avoid stressing the bumper, as undo stress will cause cracking at the bolt connections.

• Mount new hitch and Bumper assembly on van. Depending on condition of van, this is a good time to put some rust preventative paint coating or wax inside the frame boxes. Slide side pieces into frame pockets. Coat the 12mm bolts with either Anti-Seize or Blue Lock-tite, (preferred), then install the bolts and washers through the frame and into the hitch. The wavy washers go between the bolt head and the flat washer. It will take some work to get all six bolts lined up and started. Use hand wrench (18 or 19mm) to start the threads. Do not tighten until all six bolts are started. You do not want to strip the welded nuts. Before final tightening of the mounting bolts, reattach the screws for the side pieces. Make sure everything lines up before final tightening. If all okay, tighten all bolts securely!

• Go show off your new hitch! You are now finished!

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