Installation Instructions for T-Connector Adapter for Toyota Sienna

Part Numbers:

• 118498

Tools Required:

• 10mm Socket & Ratchet or 10mm Wrench
• 12mm Socket & Ratchet or 12mm Wrench
• Phillips Head Screwdriver
• Test Probe
• Drill (3/32” Drill Bit)
• Wire Crimpers
• Wire Cutters
• Trim Panel Remover

Step-by-Step Instructions:

1. Remove the Taillight Assemblies:

   • Open the rear tailgate and remove two bolts securing each taillight.
   • Carefully pry the taillight housings rearward, avoiding damage to the alignment tabs.
   • Repeat for the passenger side.

2. Disconnect the Wiring Harness:

   • Locate the taillight wiring harness on both sides of the vehicle.
   • Separate the connectors, ensuring not to break the locking tabs.
   • Clean the connector surfaces to remove dirt.

3. Remove Interior Panels:

   • Temporarily remove the rear threshold plate by removing the cargo clips.
   • Remove the jack storage compartment door on the passenger side.
   • Carefully pull back the interior trim panels on both sides using a trim panel remover.

4. Mount the Black Box:

   • Locate a suitable mounting location inside the rear quarter panel on the passenger side.
   • Clean the area with a 50/50 water/alcohol solution.
   • Mount the black box using the provided double-sided tape.

5. Connect the Passenger-Side T-Connector:

   • Route the T-Connector ends with green and brown/red wires through the opening on the passenger side.
   • Insert the T-Connector ends between the vehicle wiring connectors and lock them into place.

6. Connect the Driver-Side T-Connector:

   • Route the T-Connector end with the yellow wire to the driver’s side behind the panels and along the threshold.
   • Repeat Step 5 for the driver-side T-Connector with the yellow wire.

7. Ground the White Wire:

   • Locate a suitable grounding point near the connectors.
   • Secure the white wire with the provided ring terminal under an existing screw or by drilling a 3/32” hole.

   Warning:

   • Ensure all other ground connections are secure when removing and reattaching the ground stud.

8. Connect the Power Wire:

   • Disconnect the negative (-) battery cable.
   • Cut the yellow fuse holder wire and attach the ring terminal to the positive (+) battery cable.
   • Connect the other end of the fuse holder to the black 12-gauge wire using the yellow butt connector.

9. Route the Black Wire:

   • Route the black wire through a grommet and along the exterior frame or follow existing wiring along the thresholds into the engine compartment up to the battery.

10. Connect the Power Wire to the Black Box:

    • Connect the other end of the black 12-gauge wire to the red power wire on the T-Connector’s black box using the provided yellow butt connector.

11. Reconnect the Battery:

    • Reconnect the negative (-) battery cable.
    • Insert the 10-amp fuse into the fuse holder.

    Warning:

    • All connections must be complete for the T-Connector to function properly.
    • Test and verify the installation with a test light or trailer.

12. Secure and Reassemble:

    • Secure all loose wires with the provided cable ties.
    • Reinstall the taillight assemblies, panels, and other items removed during installation.

13. Store the 4-Flat Connector:

    • Store the 4-flat connector in the jack storage compartment when not in use.
    • Route the 4-flat harness through the rear tailgate/door seal when in use.

    Specifications:

    • Max. stop/turn light: 1 per side (2.1 amps)
    • Max. tail lights: (5.6 amps)

Safety Notes:

• Overloading circuits can cause fires. Do not exceed the towing manufacturer’s rating or the specified maximum ratings.
• Always follow all safety precautions and use safety glasses during installation.

Manufacturer Notes:

• Refer to the vehicle owner’s manual and instruction sheet for additional details.

Installation Instructions for T-Connector Adapter for Vehicle

Part Numbers:

• 118498

Tools Required:

• 10mm Socket & Ratchet or 10mm Wrench
• 12mm Socket & Ratchet or 12mm Wrench
• Phillips Head Screwdriver
• Test Probe
• Drill (3/32” Drill Bit)
• Wire Crimpers
• Wire Cutters
• Trim Panel Remover

Step-by-Step Instructions:

1. Remove the Taillight Assemblies:

   • Open the rear tailgate and remove two bolts securing each taillight.
   • Carefully pry the taillight housings rearward, avoiding damage to the alignment tabs.
   • Repeat for the passenger side.

2. Disconnect the Wiring Harness:

   • Locate the taillight wiring harness on both sides of the vehicle.
   • Separate the connectors, ensuring not to break the locking tabs.
   • Clean the connector surfaces to remove dirt.

3. Remove Interior Panels:

   • Temporarily remove the rear threshold plate by removing the cargo clips.
   • Remove the jack storage compartment door on the passenger side.
   • Carefully pull back the interior trim panels on both sides using a trim panel remover.

4. Mount the Black Box:

   • Locate a suitable mounting location inside the rear quarter panel on the passenger side.
   • Clean the area with a 50/50 water/alcohol solution.
   • Mount the black box using the provided double-sided tape.

5. Connect the Passenger-Side T-Connector:

   • Route the T-Connector ends with green and brown/red wires through the opening on the passenger side.
   • Insert the T-Connector ends between the vehicle wiring connectors and lock them into place.

6. Connect the Driver-Side T-Connector:

   • Route the T-Connector end with the yellow wire to the driver’s side behind the panels and along the threshold.
   • Repeat Step 5 for the driver-side T-Connector with the yellow wire.

7. Ground the White Wire:

   • Locate a suitable grounding point near the connectors.
   • Secure the white wire with the provided ring terminal under an existing screw or by drilling a 3/32” hole.

   Warning:

   • Ensure all other ground connections are secure when removing and reattaching the ground stud.

8. Connect the Power Wire:

   • Disconnect the negative (-) battery cable.
   • Cut the yellow fuse holder wire and attach the ring terminal to the positive (+) battery cable.
   • Connect the other end of the fuse holder to the black 12-gauge wire using the yellow butt connector.

9. Route the Black Wire:

   • Route the black wire through a grommet and along the exterior frame or follow existing wiring along the thresholds into the engine compartment up to the battery.

10. Connect the Power Wire to the Black Box:

    • Connect the other end of the black 12-gauge wire to the red power wire on the T-Connector’s black box using the provided yellow butt connector.

11. Reconnect the Battery:

    • Reconnect the negative (-) battery cable.
    • Insert the 10-amp fuse into the fuse holder.

    Warning:

    • All connections must be complete for the T-Connector to function properly.
    • Test and verify the installation with a test light or trailer.

12. Secure and Reassemble:

    • Secure all loose wires with the provided cable ties.
    • Reinstall the taillight assemblies, panels, and other items removed during installation.

13. Store the 4-Flat Connector:

    • Store the 4-flat connector in the jack storage compartment when not in use.
    • Route the 4-flat harness through the rear tailgate/door seal when in use.

    Specifications:

    • Max. stop/turn light: 1 per side (2.1 amps)
    • Max. tail lights: (5.6 amps)

Safety Notes:

• Overloading circuits can cause fires. Do not exceed the towing manufacturer’s rating or the specified maximum ratings.
• Always follow all safety precautions and use safety glasses during installation.

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.

Warranty Information:

• This product is covered by a [warranty period]. 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.

Manufacturer Notes:

• Refer to the vehicle owner’s manual and instruction sheet for additional details.

Installation Instructions for 4-Way to 7-Way Adapter and Brake Control Wiring

Tools Required:

• Phillips Head Screwdriver
• Drill with 3/32" Drill Bit
• 10mm Socket & Ratchet or Wrench
• Wire Crimpers
• Wire Cutters
• Test Light or Multimeter
• Cable Ties

Part 1: Install the 4-Way to 7-Way Adapter

Step-by-Step Instructions:

1. Mount the Adapter:

   • Choose a suitable mounting point on the vehicle, typically near the hitch.
   • Use the provided bracket and screws to secure the adapter.

2. Connect the 4-Flat Plug:

   • Plug the 4-flat connector on the adapter into the existing 4-flat plug on the vehicle.
   • This connection enables tail lights, left turn, and right turn signals.

3. Ground the Adapter:

   • Locate a clean, solid grounding point near the adapter.
   • Drill a 3/32" hole if necessary and secure the white ground wire from the adapter using the provided screw and eyelet.

4. Leave Additional Wires Disconnected:

   • The following wires will remain disconnected until Part 2:
     • Black Wire: Power from the battery.
     • Blue Wire: Brake control output.
     • Yellow Wire: Reverse light (optional; leave disconnected unless needed).

5. Test Initial Connection:

   • Use a test light or trailer to verify functionality of the 4-way connections (tail lights, turn signals).

Part 2: Install Brake Control Wiring

Step-by-Step Instructions:

1. Mount Circuit Breakers:

   • Install two 30A circuit breakers on the firewall or another suitable location near the battery.
   • Use self-tapping screws to mount them securely.

2. Route Power Wires:

   • Connect the black 12-gauge wire from the 7-way adapter to the auxiliary side of one circuit breaker (this powers the 7-way socket).
   • Run a heavy-gauge wire from the battery's positive terminal to the battery side of this circuit breaker, using a ring terminal.
   • Run another heavy-gauge wire from the battery's positive terminal to the auxiliary side of the second circuit breaker (for the brake controller).

3. Install the Brake Controller:

   • Mount the brake controller under the dash on a firm surface.
   • Use the following connections:
     • Red Wire: Connect to the cold side of the brake switch (active only when the brake pedal is pressed).
     • Blue Wire: Connect to the blue wire on the 7-way adapter for trailer brakes.
     • White Wire: Connect to a solid ground point on the vehicle body.
     • Black Wire: Connect to the auxiliary side of the second 30A circuit breaker (provides power to the brake controller).

4. Optional: Connect Reverse Light Circuit:

   • If the trailer has a reverse light circuit, connect the yellow wire from the 7-way adapter to the vehicle’s reverse light circuit.

5. Reconnect the Battery:

   • Reattach the negative battery cable and ensure all connections are secure.
   • Insert the fuses into both circuit breakers.

6. Secure All Wires:

   • Use cable ties to secure all loose wires and prevent damage or rattling.

7. Test the System:

   • Verify functionality of all circuits (running lights, turn signals, brake lights, and brake controller output).
   • If applicable, test the reverse light circuit.

Notes:

• Most installations will only require connecting the black and blue wires from the 7-way adapter.
• Leave the yellow wire disconnected unless the trailer has a reverse light or surge brake lockout circuit.
• Always adhere to safety guidelines and verify all connections before use.

Warning: Incorrect wiring can cause damage to the vehicle or trailer. Test all connections carefully before use.

Installation Instructions for 4-Way to 7-Way Adapter and Brake Control Wiring

Tools Required:

• Phillips Head Screwdriver
• Drill with 3/32" Drill Bit
• 10mm Socket & Ratchet or Wrench
• Wire Crimpers
• Wire Cutters
• Test Light or Multimeter
• Cable Ties

Part 1: Install the 4-Way to 7-Way Adapter

Step-by-Step Instructions:

1. Mount the Adapter:

   • Choose a suitable mounting point on the vehicle, typically near the hitch.
   • Use the provided bracket and screws to secure the adapter.

2. Connect the 4-Flat Plug:

   • Plug the 4-flat connector on the adapter into the existing 4-flat plug on the vehicle.
   • This connection enables tail lights, left turn, and right turn signals.

3. Ground the Adapter:

   • Locate a clean, solid grounding point near the adapter.
   • Drill a 3/32" hole if necessary and secure the white ground wire from the adapter using the provided screw and eyelet.

4. Leave Additional Wires Disconnected:

   • The following wires will remain disconnected until Part 2:
     • Black Wire: Power from the battery.
     • Blue Wire: Brake control output.
     • Yellow Wire: Reverse light (optional; leave disconnected unless needed).

5. Test Initial Connection:

   • Use a test light or trailer to verify functionality of the 4-way connections (tail lights, turn signals).

Part 2: Install Brake Control Wiring

Step-by-Step Instructions:

1. Mount Circuit Breakers:

   • Install two 30A circuit breakers on the firewall or another suitable location near the battery.
   • Use self-tapping screws to mount them securely.

2. Route Power Wires:

   • Connect the black 12-gauge wire from the 7-way adapter to the auxiliary side of one circuit breaker (this powers the 7-way socket).
   • Run a heavy-gauge wire from the battery's positive terminal to the battery side of this circuit breaker, using a ring terminal.
   • Run another heavy-gauge wire from the battery's positive terminal to the auxiliary side of the second circuit breaker (for the brake controller).

3. Install the Brake Controller:

   • Mount the brake controller under the dash on a firm surface.
   • Use the following connections:
     • Red Wire: Connect to the cold side of the brake switch (active only when the brake pedal is pressed).
     • Blue Wire: Connect to the blue wire on the 7-way adapter for trailer brakes.
     • White Wire: Connect to a solid ground point on the vehicle body.
     • Black Wire: Connect to the auxiliary side of the second 30A circuit breaker (provides power to the brake controller).

4. Optional: Connect Reverse Light Circuit:

   • If the trailer has a reverse light circuit, connect the yellow wire from the 7-way adapter to the vehicle’s reverse light circuit.

5. Reconnect the Battery:

   • Reattach the negative battery cable and ensure all connections are secure.
   • Insert the fuses into both circuit breakers.

6. Secure All Wires:

   • Use cable ties to secure all loose wires and prevent damage or rattling.

7. Test the System:

   • Verify functionality of all circuits (running lights, turn signals, brake lights, and brake controller output).
   • If applicable, test the reverse light circuit.

Notes:

• Most installations will only require connecting the black and blue wires from the 7-way adapter.
• Leave the yellow wire disconnected unless the trailer has a reverse light or surge brake lockout circuit.
• Always adhere to safety guidelines and verify all connections before use.

Warning: Incorrect wiring can cause damage to the vehicle or trailer. Test all connections carefully before use.

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.

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 Brake Control Plugin Wiring Harness (Part 20127/8506920)

Tools Required:

• Wire Stripper & Cutter
• Pliers

Overview:

This brake control plugin wiring harness is designed for quick and secure connections to your brake controller. It simplifies installation by matching functions and connecting to the corresponding wires in your vehicle.

Step-by-Step Instructions:

1. Disconnect the Battery:

   • Before beginning, disconnect the battery terminals to prevent electrical shorts or damage.

2. Connect the Wires:

   • Refer to the following chart to match the harness wires to their functions:
     • Black Wire: Battery Positive (+)
     • Red Wire: Stoplight Signal (active when the brake pedal is pressed)
     • White Wire: Ground (-)
     • Blue Wire: Output to Trailer Brakes
   • Use the appropriate connectors to secure each wire, ensuring a solid connection.

3. Secure the Wiring Harness:

   • Mount the wiring harness under the dashboard or another safe location, keeping it away from moving parts or sharp edges.

4. Plug in the Brake Controller:

   • Insert the wiring harness connector into the brake controller, ensuring it clicks securely into place.

5. Reconnect the Battery:

   • Reattach the battery terminals, ensuring they are clean and tightly connected.

6. Test the System:

   • Use a test light, circuit tester, or trailer to verify all functions:
     • The brake controller powers on.
     • The manual override activates the trailer brakes.
     • Stoplight signals and trailer brakes function properly when the brake pedal is pressed.

Notes:

• Always connect wires based on function, not color, to ensure proper operation.
• Consult your vehicle manual for fuse locations related to the brake control system.
• Verify all connections are secure and tested before use.

Warning:

• All connections must be complete for the system to function properly.
• Overloading circuits can cause damage or fire. Do not exceed the lower of the towing manufacturer’s ratings or:
  • Max. Right Turn, Left Turn, Stop, & Tail Light Circuits: 7.5 amps
  • Max. (+) Battery, Reverse, and Electric Brake Circuits: 30 amps
• Refer to your vehicle’s owner’s manual for additional instructions. Additional fusing may be required.

For safe towing and optimal performance, ensure all connections are properly secured and tested.

Installation Instructions for Brake Control Plugin Wiring Harness (Part 20127/8506920)

Tools Required:

• Wire Stripper & Cutter
• Pliers

Overview:

This brake control plugin wiring harness is designed for quick and secure connections to your brake controller. It simplifies installation by matching functions and connecting to the corresponding wires in your vehicle.

Step-by-Step Instructions:

1. Disconnect the Battery:

   • Before beginning, disconnect the battery terminals to prevent electrical shorts or damage.

2. Connect the Wires:

   • Refer to the following chart to match the harness wires to their functions:
     • Black Wire: Battery Positive (+)
     • Red Wire: Stoplight Signal (active when the brake pedal is pressed)
     • White Wire: Ground (-)
     • Blue Wire: Output to Trailer Brakes
   • Use the appropriate connectors to secure each wire, ensuring a solid connection.

3. Secure the Wiring Harness:

   • Mount the wiring harness under the dashboard or another safe location, keeping it away from moving parts or sharp edges.

4. Plug in the Brake Controller:

   • Insert the wiring harness connector into the brake controller, ensuring it clicks securely into place.

5. Reconnect the Battery:

   • Reattach the battery terminals, ensuring they are clean and tightly connected.

6. Test the System:

   • Use a test light, circuit tester, or trailer to verify all functions:
     • The brake controller powers on.
     • The manual override activates the trailer brakes.
     • Stoplight signals and trailer brakes function properly when the brake pedal is pressed.

Notes:

• Always connect wires based on function, not color, to ensure proper operation.
• Consult your vehicle manual for fuse locations related to the brake control system.
• Verify all connections are secure and tested before use.

Warning:

• All connections must be complete for the system to function properly.
• Overloading circuits can cause damage or fire. Do not exceed the lower of the towing manufacturer’s ratings or:
  • Max. Right Turn, Left Turn, Stop, & Tail Light Circuits: 7.5 amps
  • Max. (+) Battery, Reverse, and Electric Brake Circuits: 30 amps
• Refer to your vehicle’s owner’s manual for additional instructions. Additional fusing may be required.

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.

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.

Revision:

20127/8506920 Rev. A 2-6-07

Installation and Operation Instructions for Voyager Electronic Brake Control

Specifications:

• Compatible with 2, 4, 6, and 8 brake applications.
• Uses an inertial sensor for proportional braking.

Tools Required:

• Drill with a 1/8” bit.

• 6 x 3/8” screws.

• Screwdriver or wrench.

Safety Notes:

1. Avoid mounting or operating RF-generating devices (e.g., cell phones, two-way radios) closer than 12 inches to the brake control.
2. Reversing the connection to a breakaway battery will damage the brake control.
3. Disconnect the trailer plug before testing a breakaway switch to prevent damage.
4. The level adjustment is critical for proper braking response.
5. Always adhere to the vehicle's Gross Combined Weight Rating (GCWR).
6. This unit is designed for electric trailer brakes only.

Hardware List:

• Voyager brake control unit.
• Mounting bracket.
• Screws for mounting.

Installation Instructions:

Mounting the Brake Control:

1. Select a Mounting Location:
   • Ensure a flat, solid surface between -20° nose down and 70° nose up.
   • Avoid any area with potential interference or unstable mounting.
2. Attach the Mounting Bracket:
   • Use the provided #6 x 3/8” screws to securely mount the bracket.
   • Avoid over-tightening or using longer screws to prevent damage.
3. Install the Brake Control:
   • Attach the control to the bracket and adjust its position.
   • Tighten the screws snugly to secure the unit.

Leveling the Sensor:

1. Connect the trailer to the tow vehicle. The bi-colored light should glow green.
2. Turn the Power Knob to maximum (clockwise).
3. Press and hold the brake pedal.
4. Adjust the Level Knob:
   • Turn it counter-clockwise until the light changes from green to red.
   • Slowly turn it clockwise until an orange light is visible.
   • Light Settings:
     • Dim orange: Normal setting.
     • Bright orange: Aggressive braking.
     • Dim red: More aggressive braking.

Adjusting Power to Trailer Brakes:

1. Connect the trailer to the tow vehicle.
2. Turn the Power Knob to the 12 o’clock position.
3. Drive at 25 mph on a dry, level surface.
4. Apply the Manual Slide Knob:
   • If trailer brakes lock up, decrease power (turn counter-clockwise).
   • If braking is insufficient, increase power (turn clockwise).
5. Repeat until the braking is smooth and sufficient without wheel lock-up.

Fine-Tuning:

1. Make several slow stops to assess braking response.
   • If brakes grab too much, reduce aggressiveness by turning the Level Knob clockwise.
   • If braking is delayed, increase aggressiveness by turning the Level Knob counter-clockwise.

Maintenance:

• Regularly inspect connections and ensure wires are secure.
• Adjust brakes after the first 200 miles of use and every 3,000 miles thereafter.
• Keep the unit clean and free from debris.

Troubleshooting Guide:

Warranty Information:

• Limited Warranty:
  • Covers defects in materials and workmanship.
  • Excludes damage caused by improper installation, misuse, or external factors.
• Attention: This is a summary of the installation procedure. For complete installation instructions, including detailed diagrams and additional information, please download the full installation PDF.

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.