Installation Instructions for Ford Fusion, Mercury Milan, and Lincoln MKZ

Part Numbers:

• 24865
• 60282
• 77239
• 24793 (U-Haul, sold separately)

Wiring Access Location:

• PC3, PC4

Tools Required:

• Pull wire (provided)
• Lubricant or soapy water
• Wrench: 11/16"

Specifications:

• Max Gross Trailer Weight: 2,000 lb. (908 kg)
• Max Tongue Weight: 200 lb. (90.8 kg)
• Note: Do not exceed the towing vehicle manufacturer’s rating.

Step-by-Step Instructions:

1. Lower Exhaust System:

   • Detach the rubber isolators at the muffler(s) and near the rear suspension to lower the exhaust pipe.
   • Support the exhaust to prevent damage. Spray lubricant on the metal hanger rod and rubber isolator for easier removal.

2. Install Forward Carriage Bolts and Spacers:

   • Using pull wires, feed spacers and carriage bolts into the forward hole position in both frame rails.
   • Access the hole at the end of the frame rail before the impact bar. Leave the pull wire attached.
   • Note: Do not engage the bolt and spacer while inserting them into the frame.

3. Install Rearward Carriage Bolts and Spacers:

   • Feed the carriage bolt and spacer through the rearward slots at the bottom of the frame rails using the pull wires.
   • You may need to insert the bolt at an angle. Leave the pull wires in position to assist during hitch placement.

4. Position and Secure Hitch:

   • Raise the hitch into position, feeding the pull wires through the bracket holes.
   • Remove the pull wires and attach conical washers and nuts. Be careful not to push the fasteners back into the frame rail.

5. Tighten Fasteners:

   • Torque all 7/16”-14 GR5 fasteners to 50 Lb.-Ft. (68 N*M) using a torque wrench.

6. Reinstall Exhaust System:

   • Raise the exhaust system back into position and reattach the rubber isolators.

Hardware List:

• (4) Carriage Bolts: 7/16”-14 x 1-1/4” GR5
• (4) Conical Washers: 7/16”
• (4) Spacers: 1” x 2” x 3/16”
• (4) Hex Nuts: 7/16”-14

Safety Notes:

• Regularly inspect all fasteners and the hitch ball to ensure they are securely tightened.
• If the hitch is removed, plug any holes in the trunk pan or body panels to prevent water and exhaust fumes from entering.
• Replace any damaged hitch or ball immediately.
• Always observe safety precautions and wear eye protection when working beneath the vehicle.
• Do not use a torch to cut access or attachment holes.

Drawbar:

• Drawbar Kit: 3594
• Important: The drawbar must be used in the rise position only.

Compliance:

• This product complies with SAE J684, V.E.S.C. Regulation V-5, and safety requirements of the State of New York.

Additional Notes:

• Check the hitch frequently to ensure all fasteners remain tight.
• Use kinked pull wires to keep spacers independent of the bolts for easier alignment.

Installation Instructions

Part Numbers:

• 24865
• 60282
• 77239
• 24793 (U-Haul, sold separately)

Wiring Access Location:

• PC3, PC4

Tools Required:

• Pull wire (provided)
• Lubricant or soapy water
• Wrench: 11/16"

Specifications:

• Max Gross Trailer Weight: 2,000 lb. (908 kg)
• Max Tongue Weight: 200 lb. (90.8 kg)
• Note: Do not exceed the towing vehicle manufacturer’s rating.

Step-by-Step Instructions:

1. Lower Exhaust System:

   • Detach the rubber isolators at the muffler(s) and near the rear suspension to lower the exhaust pipe.
   • Support the exhaust to prevent damage. Spray lubricant on the metal hanger rod and rubber isolator for easier removal.

2. Install Forward Carriage Bolts and Spacers:

   • Using pull wires, feed spacers and carriage bolts into the forward hole position in both frame rails.
   • Access the hole at the end of the frame rail before the impact bar. Leave the pull wire attached.
   • Note: Do not engage the bolt and spacer while inserting them into the frame.

3. Install Rearward Carriage Bolts and Spacers:

   • Feed the carriage bolt and spacer through the rearward slots at the bottom of the frame rails using the pull wires.
   • You may need to insert the bolt at an angle. Leave the pull wires in position to assist during hitch placement.

4. Position and Secure Hitch:

   • Raise the hitch into position, feeding the pull wires through the bracket holes.
   • Remove the pull wires and attach conical washers and nuts. Be careful not to push the fasteners back into the frame rail.

5. Tighten Fasteners:

   • Torque all 7/16”-14 GR5 fasteners to 50 Lb.-Ft. (68 N*M) using a torque wrench.

6. Reinstall Exhaust System:

   • Raise the exhaust system back into position and reattach the rubber isolators.

Hardware List:

• (4) Carriage Bolts: 7/16”-14 x 1-1/4” GR5
• (4) Conical Washers: 7/16”
• (4) Spacers: 1” x 2” x 3/16”
• (4) Hex Nuts: 7/16”-14

Safety Notes:

• Regularly inspect all fasteners and the hitch ball to ensure they are securely tightened.
• If the hitch is removed, plug any holes in the trunk pan or body panels to prevent water and exhaust fumes from entering.
• Replace any damaged hitch or ball immediately.
• Always observe safety precautions and wear eye protection when working beneath the vehicle.
• Do not use a torch to cut access or attachment holes.

Drawbar:

• Drawbar Kit: 3594
• Important: The drawbar must be used in the rise position only.

Compliance:

• This product complies with SAE J684, V.E.S.C. Regulation V-5, and safety requirements of the State of New York.

Additional Notes:

• Check the hitch frequently to ensure all fasteners remain tight.
• Use kinked pull wires to keep spacers independent of the bolts for easier alignment.

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.

For 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.

Warranty Information:

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