Installation Instructions for Chevrolet/GMC Pickup, Dodge Pickup, Dodge Ramcharger, Ford Pickup (1980 and Later), Ford Bronco, Ford F350 Super Duty Cab & Chassis, International Pickup, and Plymouth Trailduster

Part Numbers:

• 41504
• 37081
• 44143
• 87480

Wiring Access Location:

• PU1, PU2

Tools Required:

• Wrenches: 3/4", 13/16", 7/8"
• Drill with 1/2" Drill Bit

Installation Time:

• Estimated: Not specified

Step-by-Step Instructions:

1. Remove Spare Tire:

   • Remove the spare tire from the vehicle.
   • Note: To retain under-box tire storage, the spare tire carrier may need to be relocated or modified.
   • For Ford models with 16" spare tires, adjust the spare tire cradle to maintain proper storage after hitch installation.

2. Measure Frame Width:

   • For 34" frames: Position side brackets with mounting flanges pointing inboard.
   • For 38" frames: Position side brackets with mounting flanges pointing outboard.

3. Position Side Brackets:

   • Lift the side bracket into position, ensuring the rearmost mounting tab aligns with the end of the vehicle frame.
   • Clamp the bracket to the frame.

4. Drill Holes:

   • Using the slotted holes in the bracket as a guide, drill six (6) 1/2" diameter holes in the frame.
   • Note: Existing holes in the frame may be used if available.

5. Install Side Bracket Fasteners:

   • Place blocks inside the frame and install the provided hardware as shown in the instructions.
   • Do not tighten the fasteners at this stage.

6. Special Installation for Ford Pickups (1980 and Later):

   • These models require the 1685 Fastener Kit (sold separately).

7. Repeat for Opposite Side:

   • Repeat Steps 3, 4, and 5 on the opposite side of the vehicle.

8. Install Crosstube Assembly:

   • Position the crosstube between the side brackets.
   • Secure it using the provided bolts, flat washers, and flanged locknuts.
   • Torque to 95 lb-ft (129 N*m).

9. Tighten All Side Bracket Fasteners:

   • Torque the side bracket fasteners to 75 lb-ft (102 N*m).

Torque Specifications:

• Crosstube Fasteners: 95 lb-ft (129 N*m)
• Side Bracket Fasteners: 75 lb-ft (102 N*m)

Hardware List:

• (6) Carriage Bolts, 1/2"-13 x 1.75"
• (6) Carriage Bolts, 1/2"-13 x 2.25" (*)
• (6) Hex Bolts, 1/2"-20 x 1.50"
• (6) Conical Washers, 1/2"
• (6) Flat Washers
• (6) Flange Locknuts, 1/2"-20
• (6) Hex Nuts, 1/2"-13
• (2) Blocks, 1/4" x 1-1/2" x 2" (*)
• (2) Bevel Washers (*)
• (2) Blocks, 5/8" x 1" x 2" (*)

(* Included in the 1685 Fastener Kit, sold separately for Ford models)

Safety Notes:

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

Specifications:

• Weight Carrying (Ball Mount):
  • Max Gross Trailer Weight: 5,000 lb (2,270 kg)
  • Max Tongue Weight: 500 lb (227 kg)
• Weight Distributing:
  • Max Gross Trailer Weight: 10,000 lb (4,540 kg)
  • Max Tongue Weight: 1,000 lb (454 kg)

Additional Notes:

• For vehicles equipped with "Deep Drop" step bumpers, 1981 and later Chevrolet/GMC models require the removal of support brackets from the frame.
• This product complies with V.E.S.C. Regulation V-5 and SAE J684 safety standards.

Installation Instructions for Pickup Trucks and SUVs

Part Numbers:

• 41504
• 37081
• 44143
• 87480

Wiring Access Location:

• PU1, PU2

Tools Required:

• Wrenches: 3/4", 13/16", 7/8"
• Drill with 1/2" Drill Bit

Installation Time:

• Estimated: Not specified

Step-by-Step Instructions:

1. Remove Spare Tire:

   • Remove the spare tire from the vehicle.
   • Note: To retain under-box tire storage, the spare tire carrier may need to be relocated or modified.
   • For Ford models with 16" spare tires, adjust the spare tire cradle to maintain proper storage after hitch installation.

2. Measure Frame Width:

   • For 34" frames: Position side brackets with mounting flanges pointing inboard.
   • For 38" frames: Position side brackets with mounting flanges pointing outboard.

3. Position Side Brackets:

   • Lift the side bracket into position, ensuring the rearmost mounting tab aligns with the end of the vehicle frame.
   • Clamp the bracket to the frame.

4. Drill Holes:

   • Using the slotted holes in the bracket as a guide, drill six (6) 1/2" diameter holes in the frame.
   • Note: Existing holes in the frame may be used if available.

5. Install Side Bracket Fasteners:

   • Place blocks inside the frame and install the provided hardware as shown in the instructions.
   • Do not tighten the fasteners at this stage.

6. Special Installation for 1980 and Later Ford Pickups:

   • These models require the 1685 Fastener Kit (sold separately).

7. Repeat for Opposite Side:

   • Repeat Steps 3, 4, and 5 on the opposite side of the vehicle.

8. Install Crosstube Assembly:

   • Position the crosstube between the side brackets.
   • Secure it using the provided bolts, flat washers, and flanged locknuts.
   • Torque to 95 lb-ft (129 N*m).

9. Tighten All Side Bracket Fasteners:

   • Torque the side bracket fasteners to 75 lb-ft (102 N*m).

Torque Specifications:

• Crosstube Fasteners: 95 lb-ft (129 N*m)
• Side Bracket Fasteners: 75 lb-ft (102 N*m)

Hardware List:

• (6) Carriage Bolts, 1/2"-13 x 1.75"
• (6) Carriage Bolts, 1/2"-13 x 2.25" (*)
• (6) Hex Bolts, 1/2"-20 x 1.50"
• (6) Conical Washers, 1/2"
• (6) Flat Washers
• (6) Flange Locknuts, 1/2"-20
• (6) Hex Nuts, 1/2"-13
• (2) Blocks, 1/4" x 1-1/2" x 2" (*)
• (2) Bevel Washers (*)
• (2) Blocks, 5/8" x 1" x 2" (*)

(* Included in the 1685 Fastener Kit, sold separately for Ford models)

Safety Notes:

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

Specifications:

• Weight Carrying (Ball Mount):
  • Max Gross Trailer Weight: 5,000 lb (2,270 kg)
  • Max Tongue Weight: 500 lb (227 kg)
• Weight Distributing:
  • Max Gross Trailer Weight: 10,000 lb (4,540 kg)
  • Max Tongue Weight: 1,000 lb (454 kg)

Additional Notes:

• For vehicles equipped with "Deep Drop" step bumpers, 1981 and later Chevrolet/GMC models require the removal of support brackets from the frame.
• This product complies with V.E.S.C. Regulation V-5 and SAE J684 safety standards.

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