Installation Instructions for Dodge, Ford, and Plymouth Vehicles

Part Numbers:

• 75038

Applicable Vehicles:

• Dodge D&W Series Pickup
• Dodge Ramcharger
• Ford Bronco (Full Size)
• Ford F-Series Pickup (with 37.5" frame)
• Plymouth Trailduster

Wiring Access Location:

• PU1, PU2

Tools Required:

• Drill Bits: 1/2"
• Wrenches: 3/4", 7/8" (Torque Wrench Required)

Specifications:

• Weight Carrying Capacity:
  • Trailer Weight: 5,000 lbs
  • Tongue Weight: 500 lbs
• Weight Distributing Capacity:
  • Trailer Weight: 8,000 lbs
  • Tongue Weight: 800 lbs

Step-by-Step Instructions:

1. Remove Spare Tire:

   • Where applicable, remove the spare tire and carrier from the vehicle.

2. Prepare Frame Rail:

   • Remove undercoating from the attachment surfaces.
   • Position the receiver on the vehicle, ensuring it is centered and that the formed depression in the side bracket aligns over the rivet, if present.

3. Drill Holes:

   • Using the receiver as a template, drill 1/2" holes into the frame.

4. Install Fasteners:

   • Install all fasteners as shown in the diagram, placing the blocks inside the vehicle frame.
   • Tighten the nuts on 1/2"-13 GR5 carriage bolts to 75 lb-ft.
   • Tighten the locknuts on 1/2"-20 GR5 hex bolts to 95 lb-ft.

5. Adjust Spare Tire Carrier (If Applicable):

   • For vehicles retaining under-vehicle spare tire stowage, modify or relocate the spare tire carrier. Ensure the relocated carrier and tire do not contact brake lines, rear axle, or other safety-related components.

6. Ford F-Series Pickup Applications:

   • Adjust the bumper brackets if necessary to provide clearance for the hitch side brackets.

7. Special Note for Dodge Ramcharger and Trailduster:

   • Drill out the rear frame rivet for receiver attachment. If the receiver is removed, reinstall the 1/2"-20 x 1-3/4" GR5 hex bolts (tightened to 95 lb-ft) to maintain the connection between the frame and crossmember.

Hardware List:

• (4) Carriage Bolt 1/2"-13 x 1-3/4" GR5
• (4) 1/4" x 1-1/2" x 2" Blocks
• (4) Lock Washer
• (4) Hex Nut

Safety Notes:

• Regularly inspect the hitch and fasteners to ensure secure attachment.
• Replace damaged hitches or balls immediately.
• Plug any holes in the trunk pan or body panels if the hitch is removed to prevent water or exhaust fumes from entering.
• Always wear safety glasses when working beneath the vehicle.
• Do not cut access or attachment holes with a torch.

Compliance:

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

Additional Notes:

• Installation time for professional installers is approximately 1 hour.
• Follow all torque specifications and ensure proper alignment during installation.

Installation Instructions for Dodge, Ford, and Plymouth Vehicles

Part Numbers:

• 75038

Applicable Vehicles:

• Dodge D&W Series Pickup
• Dodge Ramcharger
• Ford Bronco (Full Size)
• Ford F-Series Pickup (with 37.5" frame)
• Plymouth Trailduster

Wiring Access Location:

• PU1, PU2

Tools Required:

• Drill Bits: 1/2"
• Wrenches: 3/4", 7/8" (Torque Wrench Required)

Specifications:

• Weight Carrying Capacity:
  • Trailer Weight: 5,000 lbs
  • Tongue Weight: 500 lbs
• Weight Distributing Capacity:
  • Trailer Weight: 8,000 lbs
  • Tongue Weight: 800 lbs

Step-by-Step Instructions:

1. Remove Spare Tire

   • Where applicable, remove the spare tire and carrier from the vehicle.

2. Prepare Frame Rail

   • Remove undercoating from the attachment surfaces.
   • Position the receiver on the vehicle, ensuring it is centered and that the formed depression in the side bracket aligns over the rivet, if present.

3. Drill Holes

   • Using the receiver as a template, drill 1/2" holes into the frame.

4. Install Fasteners

   • Install all fasteners as shown in the diagram, placing the blocks inside the vehicle frame.
   • Tighten the nuts on 1/2"-13 GR5 carriage bolts to 75 lb-ft.
   • Tighten the locknuts on 1/2"-20 GR5 hex bolts to 95 lb-ft.

5. Adjust Spare Tire Carrier (If Applicable)

   • For vehicles retaining under-vehicle spare tire stowage, modify or relocate the spare tire carrier.
   • Ensure the relocated carrier and tire do not contact brake lines, rear axle, or other safety-related components.

6. Ford F-Series Pickup Applications

   • Adjust the bumper brackets if necessary to provide clearance for the hitch side brackets.

7. Special Note for Dodge Ramcharger and Trailduster

   • Drill out the rear frame rivet for receiver attachment.
   • If the receiver is removed, reinstall the 1/2"-20 x 1-3/4" GR5 hex bolts (tightened to 95 lb-ft) to maintain the connection between the frame and crossmember.

Hardware List:

• (4) 1/2"-13 x 1-3/4" GR5 Carriage Bolts
• (4) 1/4" x 1-1/2" x 2" Blocks
• (4) Lock Washers
• (4) Hex Nuts

Safety Notes:

• Regularly inspect the hitch and fasteners to ensure secure attachment.
• Replace damaged hitches or balls immediately.
• Plug any holes in the trunk pan or body panels if the hitch is removed to prevent water or exhaust fumes from entering.
• Always wear safety glasses when working beneath the vehicle.
• Do not cut access or attachment holes with a torch.

Compliance:

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

General Notes:

Attention: This is a summary of the installation procedure. For complete installation instructions, including diagrams and detailed information, please download the full installation PDF.

Warranty Information:

For warranty coverage details, including duration and terms, 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.

End of Instructions

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