Installation Instructions for Chevrolet & GMC Vans

Part Numbers:

• 41121
• 87481

Wiring Access Location:

• Not specified

Tools Required:

• Ratchet
• Torque Wrench
• 9/16" Wrench and Socket
• 3/4" Wrench and Socket

Installation Time:

• Estimated: Not specified

Step-by-Step Instructions:

1. Remove Bumper Support Brackets:

   • Remove the two lower bumper support brackets (one per side).
   • Save the bolts and washers.
   • Return the brackets to the vehicle owner.

2. Install Side Brackets:

   • Place the left and right side brackets against the bottom of the vehicle frame.
   • Attach with four (4) 1/2" bolts and washers removed in Step 1.
   • Leave the bolts loose for now.

3. Install Bumper Bolts:

   • Install two (2) 3/8" bumper bolts (removed in Step 1), along with two (2) 3/8" serrated washers and two (2) 3/8" lock nuts (provided in the parts package).
   • Leave the lock nuts loose at this time.

   Warning:

   • Two 3/8" lock nuts must be used with two 3/8" bumper bolts to ensure the receiver does not loosen or separate from the vehicle.

4. Fishwire Carriage Bolts:

   • Screw the pull wire onto a 1/2" carriage bolt.
   • Feed the pull wire through a bolt plate and the large hole in the outboard side of the frame.
   • Pull it out through the bottom hole of the frame.
   • Repeat for the other side.
   • Install two (2) 1/2" serrated washers, lock washers, and nuts on the bolts.
   • Leave the nuts loose at this time.

5. Tighten Bolts and Nuts:

   • Tighten bolts and nuts in the following order to ensure proper alignment:
     • Torque the two (2) 3/8" lock nuts on the bumper to 30 ft-lb.
     • Torque the 1/2" nuts and bolts to 75 ft-lb.

Torque Specifications:

• 3/8" lock nuts: 30 ft-lb
• 1/2" nuts and bolts: 75 ft-lb

Hardware List:

• (4) 1/2" Carriage Bolts
• (4) 1/2" Serrated Washers
• (4) 1/2" Nuts
• (4) Bolt Plates
• (2) 3/8" Bumper Bolts
• (2) 3/8" Serrated Washers
• (2) 3/8" Lock Nuts
• (1) 1/2" Pull Wire

Safety Notes:

• Do not lubricate threads, as bolt failure may occur due to over-tightening.
• Do not drill or weld to this hitch.
• Regularly check the hitch to ensure all fasteners are tight and properly installed.

Specifications:

• Weight Carrying:
  • Max Gross Trailer Weight: 5,000 lb
  • Max Tongue Weight: 500 lb
• Weight Distributing:
  • Max Gross Trailer Weight: 10,000 lb
  • Max Tongue Weight: 1,000 lb

Additional Notes:

• Use only bolts, lock nuts, and washers supplied or approved by Towing Products for installation.
• This product complies with VESC regulation V-5 and is certified for safety specifications in New York State.

Installation Instructions for Vans

Part Numbers:

• 41121
• 87481

Wiring Access Location:

• Not specified

Tools Required:

• Ratchet
• Torque Wrench
• 9/16" Wrench and Socket
• 3/4" Wrench and Socket

Installation Time:

• Estimated: Not specified

Step-by-Step Instructions:

1. Remove Bumper Support Brackets:

   • Remove the two lower bumper support brackets (one per side).
   • Save the bolts and washers.
   • Return the brackets to the vehicle owner.

2. Install Side Brackets:

   • Place the left and right side brackets against the bottom of the vehicle frame.
   • Attach with four (4) 1/2" bolts and washers removed in Step 1.
   • Leave the bolts loose for now.

3. Install Bumper Bolts:

   • Install two (2) 3/8" bumper bolts (removed in Step 1), along with two (2) 3/8" serrated washers and two (2) 3/8" lock nuts (provided in the parts package).
   • Leave the lock nuts loose at this time.

   Warning:

   • Two 3/8" lock nuts must be used with two 3/8" bumper bolts to ensure the receiver does not loosen or separate from the vehicle.

4. Fishwire Carriage Bolts:

   • Screw the pull wire onto a 1/2" carriage bolt.
   • Feed the pull wire through a bolt plate and the large hole in the outboard side of the frame.
   • Pull it out through the bottom hole of the frame.
   • Repeat for the other side.
   • Install two (2) 1/2" serrated washers, lock washers, and nuts on the bolts.
   • Leave the nuts loose at this time.

5. Tighten Bolts and Nuts:

   • Tighten bolts and nuts in the following order to ensure proper alignment:
     • Torque the two (2) 3/8" lock nuts on the bumper to 30 ft-lb.
     • Torque the 1/2" nuts and bolts to 75 ft-lb.

Torque Specifications:

• 3/8" lock nuts: 30 ft-lb
• 1/2" nuts and bolts: 75 ft-lb

Hardware List:

• (4) 1/2" Carriage Bolts
• (4) 1/2" Serrated Washers
• (4) 1/2" Nuts
• (4) Bolt Plates
• (2) 3/8" Bumper Bolts
• (2) 3/8" Serrated Washers
• (2) 3/8" Lock Nuts
• (1) 1/2" Pull Wire

Safety Notes:

• Do not lubricate threads, as bolt failure may occur due to over-tightening.
• Do not drill or weld to this hitch.
• Regularly check the hitch to ensure all fasteners are tight and properly installed.

Specifications:

• Weight Carrying:
  • Max Gross Trailer Weight: 5,000 lb
  • Max Tongue Weight: 500 lb
• Weight Distributing:
  • Max Gross Trailer Weight: 10,000 lb
  • Max Tongue Weight: 1,000 lb

Additional Notes:

• Use only bolts, lock nuts, and washers supplied or approved by Towing Products for installation.
• This product complies with VESC regulation V-5 and is certified for safety specifications in New York State.

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