Installation Instructions for Ford Explorer, Mazda Navajo, and Mercury Mountaineer

Part Numbers:

• 75083
• 70647
• 44067
• 33051
• 78166 UH

Wiring Access Location:

• SUV1, SUV2

Tools Required:

• Wrenches: 13/16", 7/8", 15/16"
• Drill Bits: 1/2"

Step-by-Step Instructions:

1. Remove Tow Hooks (if equipped):

   • Remove tow hooks from the vehicle frame and return them to the owner for reinstallation if the hitch is later removed.

2. Position Hitch:

   • Raise the receiver into position under the vehicle, placing upright bars against the outboard vertical surface of the frame. Align the hole in the upright bar with the existing slot in the frame on both sides.

3. Loosely Install Fasteners:

   • Install fasteners through the slot in the frame and upright bar as shown in the diagram.

4. Fastener Installation by Model Year:

   • 1994 and Prior Models:
     • Use the hitch as a template and drill a 1/2" hole in the bottom of the vehicle frame on both sides. Install the remaining fasteners as shown in the diagram.
   • 1995 and Later Models:
     • Install the remaining fasteners in the hitch bracket and the bottom of the vehicle frame on both sides as shown in the diagram.

5. Tighten Fasteners:

   • Tighten all 1/2" fasteners to 75 lb-ft (102 N*m).
   • Tighten all 9/16" fasteners to 110 lb-ft (149 N*m).

Torque Specifications:

• 1/2"-13: 75 lb-ft (102 N*m)
• 9/16"-12: 110 lb-ft (149 N*m)

Hardware List:

• (2) Carriage Bolts, 1/2"-13 x 1.75"
• (2) Blocks (Frame Spacer)
• (2) Conical Washers, 1/2"
• (2) Hex Nuts, 1/2"-13
• (2) Bolts, 9/16"-12 x 2.00"
• (2) Blocks (Reinforcement Bracket Spacer)
• (2) Lock Washers, 9/16"
• (2) Hex Nuts, 9/16"-12

Safety Notes:

• Regularly inspect the hitch to ensure all fasteners and the ball are securely tightened.
• Replace any damaged hitch or ball immediately.
• If the hitch is removed, plug any holes in the frame or body panels to prevent water or exhaust fumes from entering.
• Always wear safety glasses and observe proper safety precautions when working beneath the vehicle.
• 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: 6,000 lb (2,724 kg)
  • Max Tongue Weight: 600 lb (272 kg)

Additional Notes:

• Will not fit models with a 16" spare tire (1998 and later).
• This product complies with SAE J684 and V.E.S.C. Regulation V-5 standards.
• Ensure all fasteners are properly torqued before towing.

Installation Instructions for Ford Explorer, Mazda Navajo, and Mercury Mountaineer

Part Numbers:

• 75083
• 70647
• 44067
• 33051
• 78166 UH

Wiring Access Location:

• SUV1, SUV2

Tools Required:

• Wrenches: 13/16", 7/8", 15/16"
• Drill Bits: 1/2"

Step-by-Step Instructions:

1. Remove Tow Hooks (if equipped):

   • Remove tow hooks from the vehicle frame and return them to the owner for reinstallation if the hitch is later removed.

2. Position Hitch:

   • Raise the receiver into position under the vehicle, placing upright bars against the outboard vertical surface of the frame. Align the hole in the upright bar with the existing slot in the frame on both sides.

3. Loosely Install Fasteners:

   • Install fasteners through the slot in the frame and upright bar as shown in the diagram.

4. Fastener Installation by Model Year:

   • 1994 and Prior Models:
     • Use the hitch as a template and drill a 1/2" hole in the bottom of the vehicle frame on both sides. Install the remaining fasteners as shown in the diagram.
   • 1995 and Later Models:
     • Install the remaining fasteners in the hitch bracket and the bottom of the vehicle frame on both sides as shown in the diagram.

5. Tighten Fasteners:

   • Tighten all 1/2" fasteners to 75 lb-ft (102 N*m).
   • Tighten all 9/16" fasteners to 110 lb-ft (149 N*m).

Torque Specifications:

• 1/2"-13: 75 lb-ft (102 N*m)
• 9/16"-12: 110 lb-ft (149 N*m)

Hardware List:

• (2) 1/2"-13 x 1.75" Carriage Bolts
• (2) Frame Spacer Blocks
• (2) 1/2" Conical Washers
• (2) 1/2"-13 Hex Nuts
• (2) 9/16"-12 x 2.00" Bolts
• (2) Reinforcement Bracket Spacer Blocks
• (2) 9/16" Lock Washers
• (2) 9/16"-12 Hex Nuts

Safety Notes:

• Regularly inspect the hitch to ensure all fasteners and the ball are securely tightened.
• Replace any damaged hitch or ball immediately.
• If the hitch is removed, plug any holes in the frame or body panels to prevent water or exhaust fumes from entering.
• Always wear safety glasses and observe proper safety precautions when working beneath the vehicle.
• 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: 6,000 lb (2,724 kg)
  • Max Tongue Weight: 600 lb (272 kg)

Additional Notes:

• Will not fit models with a 16" spare tire (1998 and later).
• This product complies with SAE J684 and V.E.S.C. Regulation V-5 standards.
• Ensure all fasteners are properly torqued before towing.

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.

Warranty:

The product comes with a standard 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