Installation Instructions for Toyota RAV4

Part Numbers:

• 75235
• 87697
• 44785

Applications:

• 2006-Current Toyota RAV4 (*Visit the manufacturer's website for the most up-to-date application years and trim levels.)

Tools Required:

• Ratchet
• Torque Wrench
• Safety Glasses
• Sockets: 10mm, 12mm, 17mm, 19mm
• Flat Head Screwdriver
• 6" Socket Extension
• Pliers

Installation Time:

• Approximately 20 minutes (for professional installers)

Step-by-Step Instructions:

1. Driver Side Appearance Panel Removal:

   • Use a flat head screwdriver and a 10mm socket to remove (2) plastic rivets and (1) flange nut from the driver side bottom appearance panel (see Figure 2).
   • Return the panel to the vehicle owner.

2. Tie-Down Bracket Removal:

   • Use a 17mm socket to remove (2) bolts securing the tie-down bracket (see Figure 3).

3. Lower the Exhaust:

   • Use pliers to remove (1) rubber isolator from the exhaust rod on the passenger side.

4. Exhaust Rod Removal:

   • Use a 12mm socket to remove (2) bolts securing the exhaust rod near the trunk pan (see Figure 4).
   • Return the bolts and rod to the vehicle owner.

5. Hitch Installation:

   • Raise the hitch into position over the existing weldnuts in the frame.
   • Loosely install (5) M12 bolts with conical washers into the weldnuts.
   • Note: Sandwich the hitch bracket between the frame rail and the tie-down bracket on the driver side (see Figure 1).

6. Tighten Fasteners:

   • Use a torque wrench to tighten all fasteners to 76 lb-ft (103 N·m).

7. Reinstall Exhaust Rod:

   • Attach the exhaust rod back to the rubber isolator.

8. Check Installation:

   • Verify that all fasteners are properly tightened.
   • Inspect for any interference with the hitch or surrounding components.

Hardware List:

• (5) M12 x 1.25 x 40mm CL10.9 Bolts
• (5) 1/2" Conical Washers

Safety Notes:

• Check the hitch frequently to ensure all fasteners and the ball are properly tightened.
• If the hitch is removed, plug all holes in the trunk pan or other body panels to prevent water and exhaust fumes from entering.
• Replace any damaged hitch or ball immediately.
• Follow all safety precautions when working beneath the vehicle, and wear eye protection.
• Do not cut access or attachment holes with a torch.

Specifications:

• Hitch Type and Weight Ratings:
  • Weight Carrying: Max Trailer Weight 4,500 lbs (2,043 kg), Max Tongue Weight 675 lbs (306 kg).
  • Weight Distributing: Max Trailer Weight 4,500 lbs (2,043 kg), Max Tongue Weight 675 lbs (306 kg).
• Complies with safety specifications and requirements for connecting devices and towing systems of the State of New York, V.E.S.C. Regulation V-5, and SAE J684.

Installation Instructions for Toyota RAV4

Part Numbers:

• 75235
• 87697
• 44785

Applications:

• 2006-Current Toyota RAV4
  (*Visit the manufacturer's website for the most up-to-date application years and trim levels.)

Tools Required:

• Ratchet
• Torque Wrench
• Safety Glasses
• Sockets: 10mm, 12mm, 17mm, 19mm
• Flat Head Screwdriver
• 6" Socket Extension
• Pliers

Installation Time:

• Approximately 20 minutes (for professional installers)

Step-by-Step Instructions:

1. Driver Side Appearance Panel Removal:

   • Use a flat head screwdriver and a 10mm socket to remove (2) plastic rivets and (1) flange nut from the driver side bottom appearance panel (see Figure 2).
   • Return the panel to the vehicle owner.

2. Tie-Down Bracket Removal:

   • Use a 17mm socket to remove (2) bolts securing the tie-down bracket (see Figure 3).

3. Lower the Exhaust:

   • Use pliers to remove (1) rubber isolator from the exhaust rod on the passenger side.

4. Exhaust Rod Removal:

   • Use a 12mm socket to remove (2) bolts securing the exhaust rod near the trunk pan (see Figure 4).
   • Return the bolts and rod to the vehicle owner.

5. Hitch Installation:

   • Raise the hitch into position over the existing weldnuts in the frame.
   • Loosely install (5) M12 bolts with conical washers into the weldnuts.
   • Note: Sandwich the hitch bracket between the frame rail and the tie-down bracket on the driver side (see Figure 1).

6. Tighten Fasteners:

   • Use a torque wrench to tighten all fasteners to 76 lb-ft (103 N·m).

7. Reinstall Exhaust Rod:

   • Attach the exhaust rod back to the rubber isolator.

8. Check Installation:

   • Verify that all fasteners are properly tightened.
   • Inspect for any interference with the hitch or surrounding components.

Hardware List:

• (5) M12 x 1.25 x 40mm CL10.9 Bolts
• (5) 1/2" Conical Washers

Safety Notes:

• Check the hitch frequently to ensure all fasteners and the ball are properly tightened.
• If the hitch is removed, plug all holes in the trunk pan or other body panels to prevent water and exhaust fumes from entering.
• Replace any damaged hitch or ball immediately.
• Follow all safety precautions when working beneath the vehicle, and wear eye protection.
• Do not cut access or attachment holes with a torch.

Specifications:

• Hitch Type and Weight Ratings:
  • Weight Carrying: Max Trailer Weight 4,500 lbs (2,043 kg), Max Tongue Weight 675 lbs (306 kg).
  • Weight Distributing: Max Trailer Weight 4,500 lbs (2,043 kg), Max Tongue Weight 675 lbs (306 kg).
• Complies with safety specifications and requirements for connecting devices and towing systems of the State of New York, V.E.S.C. Regulation V-5, and SAE J684.

Warranty Information:

• For complete warranty instructions, please download the full installation PDF.

Technical Support:

• For technical support and assistance, our team of experts is available to help. You can reach our tech support by visiting www.trailerjacks.com or calling 877-869-6690.

Installation Instructions for T-Connector Adapter

Part Numbers:

• 118412

Tools Required:

• Trim Panel Remover
• Phillips Head Screwdriver
• Drill with 3/32” Drill Bit
• 10mm and 12mm Wrench

Step-by-Step Instructions:

1. Prepare the Vehicle:

   • Open the rear hatch.
   • Temporarily remove the rear threshold plate, privacy screen, storage covers, and floor covering.
   • Partially remove the rear interior trim panels on both the driver and passenger sides of the vehicle.
   • Carefully remove several trim panel fasteners to free the panels. Set aside all items, taking care not to damage any parts.

2. Locate the Vehicle's Taillight Wiring Harness:

   • On both sides of the vehicle, locate the taillight wiring harness.
   • Identify the connector at the rear of the taillight assembly.
   • Carefully separate the connector, ensuring not to break the locking tabs. Clean all connector surfaces of dirt.

3. Install the Driver-Side T-Connector:

   • Attach the T-Connector ends containing the yellow and brown wires between the vehicle connectors on the driver’s side.
   • Ensure the connectors are fully inserted with locking tabs secured.

4. Route the Passenger-Side T-Connector:

   • Route the T-Connector containing the green wire below the threshold cover to the passenger side.
   • Repeat Step 3 using the T-Connector ends containing the green wire.

5. Mount the T-Connector Black Box:

   • On the driver’s side, find a flat surface in a location out of the way.
   • Mount the T-Connector’s black converter box using the provided double-sided tape.

6. Ground the White Wire:

   • Locate a suitable grounding point near the connector, such as the vehicle's frame or cross member.
   • Clean dirt and rustproofing from the area.
   • Drill a 3/32” hole and secure the white wire using the provided eyelet and screw.
   • Caution: Verify what is behind the surface before drilling to avoid damage or injury.

7. Connect the Power Wire:

   • Locate the red 12-gauge power wire from the T-Connector black box.
   • Attach the black 12-gauge wire provided in the kit.
   • Route the black wire through a grommet and along the exterior frame or follow the existing wiring along the thresholds to the engine compartment.

   Warning:

   • Avoid routing near hot pipes, heat shields, the fuel tank, or other areas that could pinch or break the wire.

8. Connect to the Vehicle Battery:

   • Disconnect the vehicle’s negative (-) battery cable.
   • Remove the fuse from the yellow fuse holder. Attach the ring terminal to the fuse holder wire and secure it to the positive (+) battery cable.
   • Connect the other end of the fuse holder to the black 12-gauge wire using the provided yellow butt connector.
   • Reconnect the negative (-) battery cable and install the 10-amp fuse into the fuse holder.

9. Secure the Wiring:

   • Use the provided cable ties to secure all loose wires.
   • Ensure the T-Connector harness is routed away from areas that could cut or pinch the wire.

10. Reassemble the Vehicle:

    • Reinstall the plastic trim panels, threshold, storage covers, and floor covering, ensuring no wires are pinched or cut during reassembly.

11. Test the Installation:

    • Verify the T-Connector functionality using a test light or trailer.

    Specifications:

    • Max. stop/turn light: 1 per side (2.1 amps)
    • Max. tail lights: (4.2 amps)

Safety Notes:

• Do not exceed the towing manufacturer’s rating or the unit specifications.
• Overloading circuits can cause fires. Ensure all connections are secure and complete.

Manufacturer Notes:

• Read and follow all vehicle warnings and installation instructions carefully.
• Refer to the vehicle owner’s manual for additional information.

Installation Instructions for T-Connector Adapter

Part Numbers:

• 118412

Tools Required:

• Trim Panel Remover
• Phillips Head Screwdriver
• Drill with 3/32” Drill Bit
• 10mm and 12mm Wrench

Step-by-Step Instructions:

1. Prepare the Vehicle:

   • Open the rear hatch.
   • Temporarily remove the rear threshold plate, privacy screen, storage covers, and floor covering.
   • Partially remove the rear interior trim panels on both the driver and passenger sides of the vehicle.
   • Carefully remove several trim panel fasteners to free the panels. Set aside all items, taking care not to damage any parts.

2. Locate the Vehicle's Taillight Wiring Harness:

   • On both sides of the vehicle, locate the taillight wiring harness.
   • Identify the connector at the rear of the taillight assembly.
   • Carefully separate the connector, ensuring not to break the locking tabs. Clean all connector surfaces of dirt.

3. Install the Driver-Side T-Connector:

   • Attach the T-Connector ends containing the yellow and brown wires between the vehicle connectors on the driver’s side.
   • Ensure the connectors are fully inserted with locking tabs secured.

4. Route the Passenger-Side T-Connector:

   • Route the T-Connector containing the green wire below the threshold cover to the passenger side.
   • Repeat Step 3 using the T-Connector ends containing the green wire.

5. Mount the T-Connector Black Box:

   • On the driver’s side, find a flat surface in a location out of the way.
   • Mount the T-Connector’s black converter box using the provided double-sided tape.

6. Ground the White Wire:

   • Locate a suitable grounding point near the connector, such as the vehicle's frame or cross member.
   • Clean dirt and rustproofing from the area.
   • Drill a 3/32” hole and secure the white wire using the provided eyelet and screw.
   • Caution: Verify what is behind the surface before drilling to avoid damage or injury.

7. Connect the Power Wire:

   • Locate the red 12-gauge power wire from the T-Connector black box.
   • Attach the black 12-gauge wire provided in the kit.
   • Route the black wire through a grommet and along the exterior frame or follow the existing wiring along the thresholds to the engine compartment.

   Warning:

   • Avoid routing near hot pipes, heat shields, the fuel tank, or other areas that could pinch or break the wire.

8. Connect to the Vehicle Battery:

   • Disconnect the vehicle’s negative (-) battery cable.
   • Remove the fuse from the yellow fuse holder. Attach the ring terminal to the fuse holder wire and secure it to the positive (+) battery cable.
   • Connect the other end of the fuse holder to the black 12-gauge wire using the provided yellow butt connector.
   • Reconnect the negative (-) battery cable and install the 10-amp fuse into the fuse holder.

9. Secure the Wiring:

   • Use the provided cable ties to secure all loose wires.
   • Ensure the T-Connector harness is routed away from areas that could cut or pinch the wire.

10. Reassemble the Vehicle:

    • Reinstall the plastic trim panels, threshold, storage covers, and floor covering, ensuring no wires are pinched or cut during reassembly.

11. Test the Installation:

    • Verify the T-Connector functionality using a test light or trailer.

Specifications:

• Max. Stop/Turn Light: 1 per side (2.1 amps)
• Max. Tail Lights: (4.2 amps)

Safety Notes:

• Do not exceed the towing manufacturer’s rating or the unit specifications.
• Overloading circuits can cause fires. Ensure all connections are secure and complete.

Attention: This is a summary of the installation procedure. For complete installation instructions, including diagrams and detailed information from the manufacturer, please download the full installation PDF.

Technical Support:
For technical support and assistance, our team of experts is available to help. You can reach our tech support by visiting www.trailerjacks.com or calling 877-869-6690.