Try as I might, two of the M10 bolts just won't thread themselves properly in to the frame. I've tried putting them in first, but it seems the actual tow bar (OEM, used) is just a little bit out - that or the holes on the frame are a few mm out.

The rest of the bolts are secure, and the two problematic ones (one per side in the same position) are in, but just not home.

My main questions are a) does anyone have any suggestions as to how to resolve this, and b) would you be comfortable towing with just 6 of the 8 bolts firmly in place? The total trailer mass I'd be pulling would be no more than 1000kg.

Enlarge the hole in towbar with round file, or get all bolts in loose before tightening fully

freelance said:

Enlarge the hole in towbar with round file, or get all bolts in loose before tightening fully

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I certainly tried the all bolts in first thing, the issue is that I can’t get them all in loose first as even if I tried putting in the two troublesome ones first, they just wouldn’t go.

I think I’m going to try the other option and widen the two holes in the bar.

Just enlarge the 2 holes that the bolts won't go to. I'd drill the bar using the next drill size up, and try again.

I'm sure it'll be secure enough while it's missing 2 bolts. The towing eye is rated at 4.5 tons, and has less bolts holding it on.

Just seen this thread, I used a tap and flat spanner and just cleared enough to get bolts in. One, however, did not comply so it has a long, thinner bolt right through.