Project Pat

The current ones are still in the car, they will not be coming out, it would damage the car too much. I have ordered new ones and have designs for them from the German forum and will see if more can be made up more cheaply as they are not cheap from Audi, as you would imagine, even with our discount from our very helpful/friendly forum dealer @CreweAudi
 
Soooo. Not strictly to do with Pat but I have the towbar installed on Scotty.

I have some video but it gets quite dark towards the end, I see a fill light in my future!

Post to follow with the video.

Regards

James
 
So a quick reprise of the tasks

1) Take off boot trim inside. More to install the wiring needed to power the trailer socket. More on this later though as the passenger side boot trim also is required to be removed.

2) Take off black bumper trim just above/in front of of the silver trim strip. I have found lifting a non clipped part is easiest and then using a small flat head screwdriver to push the clip lock mech forward towards the front of the car then releases it.

3) unscrew the hex head screws that sit underneath the trim in item 2 above.

4) Now take all safety precautions, jack the car up and remove both rear wheels and put on axel stands.

5) Now remove the rear arch liners. There are some hex head screws the same size as those on the bumper (there is a sneaky one by the strut also!) and some plastic poppers. Press the centre of the poppers in slightly and they should then be released. Do not push the centre in all the way as you need this to refit them. There are some hex head screws underneath the bumper at the corner that attach the bumper to the arch and some attaching to the liner, these also use the same hex head, remove these too. Once the screws and poppers are removed jiggle the arch liner to release and ensure you lift over the bottom dome next to the strut.

6) With the arch liners out you will now see the same hex head screws along the trailing edge (inside) of the arch closest to the bumper mating surface. There are 3 that may be fitted these are the heavily recessed ones so key you have a longer hex bit to reach it. Take these out.

7) There are now two smaller hex head screws under the centre rear of the bumper attaching the bumper to the rear underside plastic trim, remove these now.

8) Now with all of the above complete you are ready to remove the bumper. I used a small flat head screwdriver double wrapped with a microfibre cloth to lever off gently the pointy corner of the bumper where it leads up to the top of the rear wheel arch. With this gently levered out I then use my fingers and gentle pressure to release the bumper. The other side is simpler to release as the majority of the bumper is now free and can be used gently to extract the other side. The bumper can break/crack so be careful and if in doubt use a screwdriver as per the other side.

9) Removing the rear safety bar - The safety bar is held on back of the car in the same position as the Towbar so is required to be removed. There are 2 separate bars that make up the overall piece. The first is the one you can see initially with the bumper off. It is a large light silver piece, it is relative light weight and is held in with 2 bolts the go top-down through each end of the bar closest to the car. Remove the two bolts and "gently" entice it to come off. The second bar is now more visible and is the part that is mounted directly into the chassis legs where the Towbar will eventually go. It has the same 3 bolts per side as the Towbar. Be careful however as this bar is much heavier than the first piece. Remove 2 bolts from either end (leaving 1 at each end to hold the weight) then slowly back out one side until it pops off, be ready to take the weight, ideally by putting something underneath the rear of the car close to the height of the bar that it can rest on, such as a plastic box or similar. Once one side is done repeat with the other.

10) Adding the Towbar - without chassis mounting hats and then with these also - Mounting the Towbar without the hats (the pieces that are either welded into the chassis legs from factory, or require to be cut into the chassis leg with a 40.5mm holesaw and mounted with pop rivets) here is the info on these I have found from the German A2 site, which is awesome (- non factory Towbar mounting hat info -) is relatively straight forward at this stage. The 3 hex head screws/bolts at either side that were removed in step 9 are now used in the same position to mount the towbar. Firstly offer up the Towbar legs to the chassis leg openings (which are now easily visible following step 9) and slide them in, this will line up the mounting parts of the Towbar with the 3 mounting holes. Simply use the screws/bolts from the previous step to mount the Towbar in position, following the usual good practice of tightening each one up to 90% whilst locating the whole unit and then finishing off each one in turn with spread the load.

11) Adding the electrics - the official Audi electrics and also the Jaeger plug and play item - (I've not tackled this yet) - I did manage to find an official A2 Towbar electric kit on Ebay which is very lucky which I shall get on Monday (12th Aug) and then have a go installing from there. If anyone has done this before I would appreciate any advice on installation.

Photos will be added to the above along with a better video as soon as it's stopped battering down with rain or is dark, or both!

Regards

James
 
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Sanded and then wet sanded the tow bar and now painted in truck bed black.

Much nicer.
bab771b65b40de5209f901eef975f183.jpg


Regards

James
 
Lots of dirty hands at the broons household recently... what an example that is now James. Love the seats in Scotty.

Get some spit shine on the swan neck!
 
Ha ha. Oh yes. Glad you mentioned that. I've already wet sanded it (gently) to get off most of the gunk, I'll give it a better go tomorrow (as it's due to rain) but first thing is get the bumper cut and put back on then get some nice photos (weather permitting)

Regards

James
 
Has anyone any experience with a Towbar Towball that doesn't want to release. I've got it off and soaked it and worked it but for the life of me I cannot get the thing working, I have to use moley grips to turn the mechanism and it seems to not have any spring action to clip in place and that cannot be good. I'm either a total lightweight or all is not well with it? Is there a breakdown of how the mechanism in it works and how it is serviced does anyone know?
 
Has anyone any experience with a Towbar Towball that doesn't want to release. I've got it off and soaked it and worked it but for the life of me I cannot get the thing working, I have to use moley grips to turn the mechanism and it seems to not have any spring action to clip in place and that cannot be good. I'm either a total lightweight or all is not well with it? Is there a breakdown of how the mechanism in it works and how it is serviced does anyone know?
I had to dismantle the mechanism (on my PCT ball) to get it working. I'd imagine your factory one will be similar though I'm afraid I'm not brave enough to dismantle my working factory ball.
 
I was on a green hex pad (2nd hardest), with Menzerna medium cut compound. Took 5 mins. No further refining, which is definitely required but good enough to show a massive difference. More work required but very very successful.

Regards

James
 
I was on a green hex pad (2nd hardest), with Menzerna medium cut compound. Took 5 mins. No further refining, which is definitely required but good enough to show a massive difference. More work required but very very successful.

Regards

James

Wow, great work. I thought it had been wet sanded with 3000 grit to get rid of the fine scratches that well.
 
Oh that's coming on some parts for sure! I'll get video of me working on the paint so that it may help others.

Regards

James
 
Good write up James, I fitted a Tow bar to my Dad's A2 last week.

The last bit to do now is the wiring, is there any wiring diagrams kicking around so I know what wires to tap into ?
 
Good write up James, I fitted a Tow bar to my Dad's A2 last week.

The last bit to do now is the wiring, is there any wiring diagrams kicking around so I know what wires to tap into ?

Good question. I have the official Audi electric extension kit coming today (just happened to find one on Ebay) so I'll get .PDF's of the manual and upload that here if that would help you. I would recommend that you take a look at the Jaeger kit (german) that is plug and play with the rear light clusters, plus I think a positive fused tap, it looks great, but a bit spendy!

I'd be interested to hear how you got on fitting the towbar, was it Audi or GDW and if Audi was it a dealer or factory fit one that was moving?
 
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