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DELIVERY VAN 40C, 45C, 50C
026221 FITTING INSTRUCTIONS
1.
Unpack the towing bracket and check its contents against the parts list. If necessary, remove the
underseal from around the fitting points of the luggage compartment/frame members.
2.
Remove the plastic part of the running board.
Make recesses in the plastic part as indicated in detail 1a.
Modify the metal part of the anti-underrun bumper as indicated in details 1b, 1c and 1d.
For this purpose, first drill the holes as indicated in the detail drawing and then saw or grind the
groove required for the towbar to be able to pass.
Remove the fastening bolt of the superstructure from the top of the chassis at "A" (see also
details 2 and 3).
3.
Drilling holes in the chassis beam.
For Delivery Van type, all versions except 3950 wheelbase (see detail 2):
For mounting of the two side plates "1" and "2", a number of holes must be drilled. Proceed as
follows.
The holes "B", "D" and "E" are already present in the bottom flange of the chassis beam.
Mount plate "1", together with one of the counterplates "3", at the holes "B" and "D".
Mark the holes "A" and "C" on the underside of the chassis beam with a 12 mm drill. Remove
plate "1".
Drill the holes "A" and "C" through the bottom flange of the chassis beam.
Now mount the top counterplate "3", together with the spacer sleeve "4", at hole "A" in the
existing hole in the superstructure. Ensure that counterplate "3" is in line with the chassis beam
for the purpose of correct alignment of the holes.
Now drill the holes "C" and "E" through to the top flange of the chassis beam with a 12 mm drill
with a minimum length of 150 mm.
Repeat this procedure for the right-hand side.
For Delivery Van type, 3950 wheelbase (see detail 3):
For mounting of the two side plates "1" and "2", a number of holes must be drilled. Proceed as
follows.
The holes "B", "D" and "E" are already present in the bottom flange of the chassis beam.
Mount plate "1", together with one of the counterplates "3", at the holes "B" and "D".
Mark the holes "A" and "C" on the underside of the chassis beam with a 12 mm drill. Remove
plate "1".
Drill the holes "A" and "C" through the bottom flange of the chassis beam.
Now mount the top counterplate "3", together with the spacer sleeve "4", at hole "A" in the
existing hole in the superstructure. Ensure that counterplate "3" is in line with the chassis beam
for the purpose of correct alignment of the holes.
Now drill holes "C" and "D" through to the top flange of the chassis beam with a 12 mm drill with a
minimum length of 150 mm.
Repeat this procedure for the right-hand side.
4.
Mount the anti-underrun bumper again.
Ensure that the fastening bolts (at "P", see detail 1d) of the anti-underride bumper aremounted
with the bolt head on the inside of the chassis beam so that the spacer sleeves to be fitted can
pass.
5.
Mounting the two side plates "1" and "2".
For Delivery Van type, all versions except 3950 wheelbase (see detail 3):
Mount side plate "1" together with counterplate "3" at holes "B" and "D" with the M12x40 bolts,
incl. lock nuts (M12x1,75mm).
Mount one of the spacer sleeves "4" and the counterplate "3" at hole "A" by means of the bolt
M12x1,25x160.
At the holes "C" and "E", mount the spacer sleeves "4" and two counterplates "5" by means of
the bolts M12x1,25x160, incl. lock nuts (M12x1,25mm).
Caution: the mounting set contains M12 nuts with a normal screw thread (1,75mm) and M12
nuts with a fine screw thread (1,25mm). Use the correct nuts with the respective bolts.
Repeat this procedure for the right-hand side.
Mounting the two side plates "1" and "2".
For Delivery Van type, 3950 wheelbase (see detail 2):
Mount side plate "1" together with counterplate "3" at holes "B" and "E" with the M12x40 bolts,
incl. lock nuts (M12x1,75mm).
Mount one of the spacer sleeves "4" and the counterplate "3" at hole "A" with the bolt
M12x1,25x160.
At holes "C" and "D", mount the spacer sleeves "4" and two counterplates "5" by means of the
bolts M12x1,25x160, incl. lock nuts (M12x1,25mm).
Caution: the mounting set contains M12 nuts with a normal screw thread (1,75mm) and M12
nuts with a fine screw thread (1,25mm). Use the correct nuts with the respective bolts.
Repeat this procedure for the right-hand side.
6. Mount the cross beam, between the two side plates, at the holes "G" by means of the bolts
M12x40, incl. lock nuts (M12x1,75mm).
Mount the reinforcement supports "7" for lateral reinforcement (see detail 4).
For mounting at the side supports "1" and "2", use the bolts M12x50, incl. lock nuts (M12x1,75mm) .
Mount support "7" at the anti-underrun bumper by means of the bolts M10x55, incl. lock nuts and
coachwork washers (3x10.5x2.5).
7. Mount the ball at the desired height, (see detail 5) in position "a" or "b".
First mount the angle bracket "9" at hole "M" with the bolt M12x90, incl. ring 37x13x3 and lock nut
(M12x1,75mm). Then mount the coupling ball at holes "K", together with the reinforcement supports "6",
with bolts M10x100, incl. lock nuts M10.
Then at holes "L" with bolts M10x40 (10,9) incl. lock nuts M10.
For ball 611.45.783: as indicated in detail 5a or 5b.
For ball 611.44.854: as indicated in detail 5a or 5b.Page 14/13
For Rockinger vario-bloc system: in accordance with the instructions for the system.
If the ball is mounted in the top position (5a), an additional recess must be made in the
plastic part of the running board in accordance with detail 1a.
8. Secure the towbar using a torque-wrench. Torque the bolts as follows:
8.8
M6
9,5 Nm
M8
23 Nm
M10
46 Nm
M12
79 Nm
M12x100/110
M16
195Nm
280Nm
M10x1,25
49 Nm
M12x1,25
87 Nm
125Nm
M12x1,5
83 Nm
122Nm
After about 1000 km use, re-tighten the bolts and nuts to the specified torque.
9. Mount the plastic part of the running board again.
10. Bosal cannot be held responsible for any defects in the product caused by fault or by any
injudicious use whatever of the user or a person he is liable for. (sect. 185, art. 2 N.B.W.)
10.9
8.8
10.9
14 Nm
34 Nm
68 Nm
117Nm
100Nm
72 Nm
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