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DELIVERY VAN 35C/E 40C/E
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 footboard.
Make two small recesses on the underside of the plastic part of the running board, as indicated in
detail 1a.
Check that the fastening bolts of the running board are mounted with the bolt head on the inside of
the chassis beam, so that the spacer sleeves to be fitted can pass.
On the top of the chassis, at "A", remove the fastening bolt from the superstructure (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 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. 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 bolts M12x40, 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 M12x1x25x160, 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 bolts M12x40, 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 the 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.
5. 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 "6" for lateral reinforcement (see detail 4).
For mounting at the side supports "1" and "2", use the bolts M12x50, incl. lock nuts (M12x1,75mm).
6. 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. washer 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.
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 1b.
7. 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
M10x1,25
49 Nm
M12x1,25
87 Nm
M12x1,5
83 Nm
After about 1000 km use, re-tighten the bolts and nuts to the specified torque.
8. Mount the plastic part of the running board again.
9. 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
280Nm
72 Nm
125Nm
122Nm
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