Installation Instructions for Chevrolet, Ford, and GMC Pickup Trucks

Part Numbers:

• 41001
• 37087

Wiring Access Location:

• PU1, PU2

Tools Required:

• Drill Bits: 1/2"
• Wrenches: 3/4", 7/8" (Use torque wrench for all fasteners)

Specifications:

• Weight Distributing:
  • Max Trailer Weight: 10,000 lbs
  • Max Tongue Weight: 1,000 lbs
• Weight Carrying:
  • Max Trailer Weight: 6,000 lbs
  • Max Tongue Weight: 600 lbs

Step-by-Step Instructions:

1. Remove Spare Tire:

   • Remove the spare tire and carrier from the vehicle.

2. Disconnect Exhaust Pipes (Dual Exhaust Models Only):

   • Disconnect the clamp and drop the exhaust pipes on dual exhaust models.

3. Position Receiver:

   • Position the receiver on the vehicle as shown, ensuring the receiver is centered.
   • In some cases, it may align with existing holes in the frame. Remove any undercoating from the attachment surfaces.

4. Drill Holes:

   • Use the receiver as a template to drill any remaining holes in the bottom of the frame rails with a 1/2" drill bit.

5. Install Fasteners:

   • Install all fasteners as shown, placing blocks inside the vehicle frame.
   • Tighten 1/2" Grade 5 fasteners to 75 lb-ft.

6. Reconnect Exhaust:

   • Reconnect the exhaust pipes to the clamp.

7. Relocate Spare Tire:

   • To retain under-box tire storage, the spare tire carrier must be relocated and/or modified.

Notes:

• For 1981 and Later Chevrolet & GMC with Step Bumpers:
  • Remove support brackets to fit the hitch.
  • Retain the brackets for reinstallation if the hitch is removed. Step bumpers should not be used for towing with these brackets removed.

Optional Accessories:

• J-Pin: Locking stabilizing pin (order separately).

Safety Notes:

• Ensure all fasteners are properly tightened to specified torque values.
• Inspect the hitch and fasteners regularly.
• Plug any holes in the trunk pan or body panels if the hitch is removed to prevent water or exhaust fumes from entering.
• Do not cut or modify attachment holes with a torch.

Compliance:

This product complies with safety specifications and requirements for connecting devices and towing systems in the state of New York and V.E.S.C. Regulation V-5.

Additional Notes:

• Check all hitch fasteners and ball mount connections before each use.
• Ensure proper alignment and secure attachment of all components.

Installation Instructions for Pickup Trucks

Part Numbers:

• 41001
• 37087

Wiring Access Location:

• PU1, PU2

Tools Required:

• Drill Bits: 1/2"
• Wrenches: 3/4", 7/8" (Use torque wrench for all fasteners)

Specifications:

• Weight Distributing:
  • Max Trailer Weight: 10,000 lbs
  • Max Tongue Weight: 1,000 lbs
• Weight Carrying:
  • Max Trailer Weight: 6,000 lbs
  • Max Tongue Weight: 600 lbs

Step-by-Step Instructions:

1. Remove Spare Tire:

   • Remove the spare tire and carrier from the vehicle.

2. Disconnect Exhaust Pipes (Dual Exhaust Models Only):

   • Disconnect the clamp and drop the exhaust pipes on dual exhaust models.

3. Position Receiver:

   • Position the receiver on the vehicle as shown, ensuring the receiver is centered.
   • In some cases, it may align with existing holes in the frame. Remove any undercoating from the attachment surfaces.

4. Drill Holes:

   • Use the receiver as a template to drill any remaining holes in the bottom of the frame rails with a 1/2" drill bit.

5. Install Fasteners:

   • Install all fasteners as shown, placing blocks inside the vehicle frame.
   • Tighten 1/2" Grade 5 fasteners to 75 lb-ft.

6. Reconnect Exhaust:

   • Reconnect the exhaust pipes to the clamp.

7. Relocate Spare Tire:

   • To retain under-box tire storage, the spare tire carrier must be relocated and/or modified.

Notes:

• For 1981 and Later Pickup Trucks with Step Bumpers:
  • Remove support brackets to fit the hitch.
  • Retain the brackets for reinstallation if the hitch is removed. Step bumpers should not be used for towing with these brackets removed.

Optional Accessories:

• J-Pin: Locking stabilizing pin (order separately).

Safety Notes:

• Ensure all fasteners are properly tightened to specified torque values.
• Inspect the hitch and fasteners regularly.
• Plug any holes in the trunk pan or body panels if the hitch is removed to prevent water or exhaust fumes from entering.
• Do not cut or modify attachment holes with a torch.

Compliance:

This product complies with safety specifications and requirements for connecting devices and towing systems in the state of New York and V.E.S.C. Regulation V-5.

Additional Notes:

• Check all hitch fasteners and ball mount connections before each use.
• Ensure proper alignment and secure attachment of all components.

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.

Warranty:

This product is covered by a limited warranty. For complete warranty instructions, please download the full installation PDF.

Installation Instructions for Trailer Light Wiring Kit

Part Number:

• 20252

Tools Required:

• Hot Air Gun or Appropriate Heat Source
• Wire Crimpers
• Drill (3/32” Drill Bit)
• Phillips Head Screwdriver
• Circuit Tester

Step-by-Step Instructions:

Step 1: Locate the Taillight Wiring Harness

1. Access the vehicle's taillight wiring harness.
2. Using the provided instructions, identify the appropriate wires for connection:
   • Green Wire: Right Turn & Stop
   • Yellow Wire: Left Turn & Stop
   • Brown Wire: Taillights
   • White Wire: Ground

Step 2: Make the Electrical Connections

1. Match the color-coded wires from the wiring kit to the corresponding vehicle wires.

   • Use a circuit tester to verify each wire's function before connecting.
   • CAUTION: Test one wire at a time to prevent damage to electronic components.

2. Connect the wires using the provided insulated butt connectors:

   • Strip the ends of each wire and seat them properly in the connector.
   • Use a crimping tool designed for insulated splices to secure the connections.

3. Heat the connectors:

   • Apply heat directly to the center of each splice using a hot air gun.
   • Work from the center outward until the tubing recovers and adhesive flows.
   • Allow the connections to cool before inspecting for integrity.

Step 3: Ground the System

1. Locate a grounding point near the wiring harness, such as the vehicle frame or cross member.
   • Do not drill into the vehicle floor or bed.
2. Clean the area to remove dirt, rust, or undercoating.
3. Drill a 3/32" hole at the grounding point and secure the white wire using the provided eyelet and screw.

Step 4: Verify the Installation

1. Test all connections using a circuit tester or trailer:
   • Verify the functionality of taillights, turn signals, and brake lights.
   • Ensure all connections are complete and secure.
2. If issues are identified, double-check the wiring and connections for errors.

Step 5: Store the 4-Flat Connector

• Store the 4-flat connector in the rear cargo area when not in use to protect it from damage and environmental exposure.

Warnings and Notes:

• WARNING: Overloading a circuit can cause fires. Do not exceed the following limits:
  • Stop/Turn Lights: 7.5 amps (1 per side)
  • Tail Lights: 7.5 amps
• WARNING: Always verify what is behind any surface before drilling to avoid vehicle damage or injury.
• NOTE: Trailer lighting that requires more than 7.5 amps per circuit must use a Trailer Light Power Converter.
• NOTE: If your trailer requires a plug other than the 4-flat, consult your dealer for optional 6-way or 7-way adapters.

Maintenance:

• Inspect the wiring harness periodically for damage, corrosion, or loose connections.
• Reapply heat to connectors if the adhesive seal weakens.

Specifications:

• Maximum Load:
  • Stop/Turn Lights: 7.5 amps (1 per side)
  • Tail Lights: 7.5 amps
• Recommended Grounding Hole Size: 3/32 inches

Installation Instructions for Trailer Light Wiring Kit

Part Number:

• 20252

Tools Required:

• Hot Air Gun or Appropriate Heat Source
• Wire Crimpers
• Drill (3/32” Drill Bit)
• Phillips Head Screwdriver
• Circuit Tester

Step-by-Step Instructions:

Step 1: Locate the Taillight Wiring Harness

1. Access the vehicle's taillight wiring harness.
2. Using the provided instructions, identify the appropriate wires for connection:
   • Green Wire: Right Turn & Stop
   • Yellow Wire: Left Turn & Stop
   • Brown Wire: Taillights
   • White Wire: Ground

Step 2: Make the Electrical Connections

1. Match the color-coded wires from the wiring kit to the corresponding vehicle wires.

   • Use a circuit tester to verify each wire's function before connecting.
   • CAUTION: Test one wire at a time to prevent damage to electronic components.

2. Connect the wires using the provided insulated butt connectors:

   • Strip the ends of each wire and seat them properly in the connector.
   • Use a crimping tool designed for insulated splices to secure the connections.

3. Heat the connectors:

   • Apply heat directly to the center of each splice using a hot air gun.
   • Work from the center outward until the tubing recovers and adhesive flows.
   • Allow the connections to cool before inspecting for integrity.

Step 3: Ground the System

1. Locate a grounding point near the wiring harness, such as the vehicle frame or cross member.
   • Do not drill into the vehicle floor or bed.
2. Clean the area to remove dirt, rust, or undercoating.
3. Drill a 3/32" hole at the grounding point and secure the white wire using the provided eyelet and screw.

Step 4: Verify the Installation

1. Test all connections using a circuit tester or trailer:
   • Verify the functionality of taillights, turn signals, and brake lights.
   • Ensure all connections are complete and secure.
2. If issues are identified, double-check the wiring and connections for errors.

Step 5: Store the 4-Flat Connector

• Store the 4-flat connector in the rear cargo area when not in use to protect it from damage and environmental exposure.

Warnings and Notes:

• WARNING: Overloading a circuit can cause fires. Do not exceed the following limits:
  • Stop/Turn Lights: 7.5 amps (1 per side)
  • Tail Lights: 7.5 amps
• WARNING: Always verify what is behind any surface before drilling to avoid vehicle damage or injury.
• NOTE: Trailer lighting that requires more than 7.5 amps per circuit must use a Trailer Light Power Converter.
• NOTE: If your trailer requires a plug other than the 4-flat, consult your dealer for optional 6-way or 7-way adapters.

Maintenance:

• Inspect the wiring harness periodically for damage, corrosion, or loose connections.
• Reapply heat to connectors if the adhesive seal weakens.

Specifications:

• Maximum Load:
  • Stop/Turn Lights: 7.5 amps (1 per side)
  • Tail Lights: 7.5 amps
• Recommended Grounding Hole Size: 3/32 inches

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:

20252 Rev. A 2-6-07