2002-2006 Sprinter Van Front Tow Hitch Installation Instructions Download

06 Sprinter Front Carry Hitch Installation Instructions
DO NOT USE THIS HITCH FOR TOWING, PULLING OR WINCHING PURPOSES!
This hitch is designed for carry weight only. Examples of carry weight include; bicycle racks, carry
platforms, etc. Do not block headlamps, turn lamps, driver’s view of road or restrict airflow to ra-
diator and engine. Maximum carry weight is 300 pounds.
1. Front carry hitch installation is easiest if you can properly lift and support the front end of the ve-
hicle. We recommend using 2 jacks and lift under the front control arm area. Be careful where
you lift or you will damage frame crossmembers or suspension components. Jack stands with a
minimum of 6 ton rating should be used and can be placed in the transmission crossmember/
frame rail area. Installation is easiest if the front tires and fascia are removed. Remove front grill
and front fascia. Remove the 2 upper grill plastic pins, figure 1. Remove bolt, figure 2, loosen
(but do not remove) screws, figure 3 and remove grill. Remove both plastic fascia pins, figure 4.
Remove the license plate holder and the fascia bolts located underneath, figure 5. When remov-
ing the license plate holder, detach the ambient air temp sensor attached to the holder. Pull the
fascia forward and remove assembly.
2. The carry hitch frame brackets mount on the inside of the frame rails. To ensure proper fit, use a
scrapper and remove undercoating on both sides of frame rail, figure 7. It is easiest to drill the
mounting holes from the outside of the frame rail. To locate mounting holes for drilling, you will
place the right side bracket on the outside of left side frame rail. Clamp the left frame bracket in
place on the outside of the right frame rail, figure 8. The bracket must be flush back against the
jack lifting saddle, figure 9 and the lateral support plate must be sitting flat up against the bottom
of the frame rail, figure 10. Using the bracket holes as a guide, drill both 1/2” holes STRAIGHT
through the rail. The holes must be straight and you MUST use a piece of metal or wood to pro-
tect coolant and turbo hoses as you drill through the inside frame rail. Repeat the procedure us-
ing the right side frame bracket to drill the left side mounting holes. Once the 4 mounting holes
are drilled, swap the mount brackets and install the 1/2”x4” mounting bolts. Install the 4 backing
plates, flat washers and Nyloc nuts. Tighten bolts only to a snug fit.
3. Make sure the frame bracket is flat up against the lower frame rail, figure 10. Using the frame
bracket as a template, drill a 7/16” hole in the bottom of the frame rail, see figure 11. Place the
Carriage bolt retainer, figure 12, through the factory access hole in the bottom of the frame rail,
figure 13. Insert the retainer with the rectangular Carriage bolt hole (figure 15) toward the front
of the Sprinter. Using your finger, you can maneuver the retainer over the 7/16” hole you drilled.
You can also use a screwdriver to help align the retainer over the hole. Wrap the supplied fish
wire around the upper part of the Carriage bolt, see figure 14. Form the fish wire (see figure 14)
so you can work it, while holding the Carriage bolt, through the factory access hole. Place the
Carriage bolt in the retainer hole and then through the 7/16” frame rail hole. This may be the
most frustrating part of the installation. Once the bolt is partially through the frame hole and the
frame bracket, install the flat washer, lock washer and nut. Turn the nut only 2-3 turns and then
pull hard on the fish wire. It will unwrap itself from the Carriage bolt. Tighten the Carriage bolt to
a loose fit. Tighten the 1/2” mounting bolts to a loose fit. Use this same procedure for the oppo-
site lateral plate and Carriage bolt installation.
Sprinter Store is a division of Upscale Automotive, Inc.
19460 SW 89th Ave. Tualatin, OR 97062 503-692-0846 Fax 503-691-2763
sprinterstore.com
4. Lift the hitch receiver assembly in place between the frame rail brackets and install the 1/2”x1.5”
bolts, flat washers and Nyloc nuts. Begin tightening all the 1/2” bolts to a loose kit being careful to
evenly drawing the receiver assembly together and making sure the frame rail brackets seat prop-
erly. Tighten all frame rail mount 1/2” bolts to 75 pounds torque and the Carriage bolts to 50
pounds torque. Tighten all receiver to frame rail mount 1/2” bolts to 75 pounds torque.
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#2
#3
#1
#4
#5
#6
#3
#4
#7
#9
#13
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The mounting bracket in this picture
is temporarily in place for drilling the
mounting holes and not for drilling the
lateral plate holes. The brackets are
permanently mounted on the inside
of the frame rails.
#8
#9
#10
#10
#9
#13 #11
#12
#14
#15
Carriage bolt and Carriage bolt
retainer
#14
Carriage bolt with fish