Installation Instructions for Dodge Durango and Chrysler Aspen

Part Numbers:

• 75162
• 87562
• 44743
• 75151 (U-Haul)

Wiring Access Location:

• SUV1, SUV2

Tools Required:

• Knife or small hand saw
• Wrenches: 11/16", 3/4"
• Drill Bits: 1/2"

Step-by-Step Instructions:

1. Lower the spare tire.
2. Trim the styrofoam/plastic fascia support as shown in Figure 3 for U-bolt installation.
   • Note: Trimming is necessary to ensure the receiver seats properly on the vehicle crossmember.
3. Install U-bolts over the vehicle crossmember at the cutouts in the styrofoam/plastic.
4. Raise the hitch into position and loosely attach it to the U-bolts using lock washers and nuts.
5. Center the hitch on the vehicle.
   • Tighten 7/16-20 nuts to 55 lb-ft (75 N·m). The hitch should fit flat against the bottom of the vehicle crossmember.
6. Remove (4) fasteners securing the fascia to its mounting brackets. Push the fascia upward to drill through (2) holes in the hitch bar into the rear face of the vehicle crossmember. Drill (2) holes through the hitch plate and into the front face of the vehicle crossmember.
7. Install 1/2-13 x 4.00 GR5 hex bolts and hardened flat washers as shown. Attach lock washers and nuts.
   • Tighten all 1/2-13 GR5 fasteners to 75 lb-ft (102 N·m).
8. Re-install the fascia mounting fasteners.
9. Raise the spare tire back into position.

Hardware List:

• (4) 7/16-20 Hex Nuts
• (4) 7/16" Lock Washers (Plated)
• (2) 7/16-20 U-Bolts
• (2) 1/2-13 x 4.00 GR5 Hex Bolts
• (2) 1/2" Hardened Flat Washers
• (2) 1/2" Lock Washers
• (2) 1/2-13 Hex Nuts (GR2)

Safety Notes:

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

Specifications:

• Hitch Type and Weight Ratings:
  • Weight Distributing: Max Trailer Weight 9,000 lbs (4,082 kg), Max Tongue Weight 900 lbs (408 kg).
  • Weight Carrying (Ball Mount): Max Trailer Weight 6,000 lbs (2,722 kg), Max Tongue Weight 600 lbs (272 kg).
• Complies with safety specifications and requirements for connecting devices and towing systems of the State of New York, V.E.S.C. Regulation V-5, and SAE J684.

Installation Instructions for Dodge Durango and Chrysler Aspen

Part Numbers:

• 75162
• 87562
• 44743
• 75151 (U-Haul)

Wiring Access Location:

• SUV1, SUV2

Tools Required:

• Knife or small hand saw
• Wrenches: 11/16", 3/4"
• Drill Bits: 1/2"

Step-by-Step Instructions:

1. Lower the spare tire.
2. Trim the styrofoam/plastic fascia support as shown in Figure 3 for U-bolt installation.
   • Note: Trimming is necessary to ensure the receiver seats properly on the vehicle crossmember.
3. Install U-bolts over the vehicle crossmember at the cutouts in the styrofoam/plastic.
4. Raise the hitch into position and loosely attach it to the U-bolts using lock washers and nuts.
5. Center the hitch on the vehicle.
   • Tighten 7/16-20 nuts to 55 lb-ft (75 N·m). The hitch should fit flat against the bottom of the vehicle crossmember.
6. Remove (4) fasteners securing the fascia to its mounting brackets. Push the fascia upward to drill through (2) holes in the hitch bar into the rear face of the vehicle crossmember. Drill (2) holes through the hitch plate and into the front face of the vehicle crossmember.
7. Install 1/2-13 x 4.00 GR5 hex bolts and hardened flat washers as shown. Attach lock washers and nuts.
   • Tighten all 1/2-13 GR5 fasteners to 75 lb-ft (102 N·m).
8. Re-install the fascia mounting fasteners.
9. Raise the spare tire back into position.

Hardware List:

• (4) 7/16-20 Hex Nuts
• (4) 7/16" Lock Washers (Plated)
• (2) 7/16-20 U-Bolts
• (2) 1/2-13 x 4.00 GR5 Hex Bolts
• (2) 1/2" Hardened Flat Washers
• (2) 1/2" Lock Washers
• (2) 1/2-13 Hex Nuts (GR2)

Safety Notes:

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

Specifications:

• Hitch Type and Weight Ratings:
  • Weight Distributing: Max Trailer Weight 9,000 lbs (4,082 kg), Max Tongue Weight 900 lbs (408 kg).
  • Weight Carrying (Ball Mount): Max Trailer Weight 6,000 lbs (2,722 kg), Max Tongue Weight 600 lbs (272 kg).
• Complies with safety specifications and requirements for connecting devices and towing systems of the State of New York, V.E.S.C. Regulation V-5, and SAE J684.

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.

Installation Instructions for T-Connector Adapter

Part Numbers:

• 118390

Wiring Access Location:

• Rear taillight assemblies and under the vehicle near the bumper.

Tools Required:

• Trim panel remover.
• Wire crimpers.
• Wire cutters.
• Pliers.

Step-by-Step Instructions:

1. Access Taillight Wiring:

   • Open the tailgate and remove the vehicle’s right-side taillight assembly by removing the two clips holding it in place.
   • Carefully pry the housing away from the vehicle, ensuring the alignment tabs are not broken.
   • Repeat the process for the left-side taillight assembly.

2. Disconnect Wiring Harness:

   • Slide the red locking tab on the vehicle wiring harness connectors to the unlocked position.
   • Disconnect the wiring harness from both taillight sockets.

3. Install T-Connector:

   • Plug the T-Connector end with the yellow wire between the driver’s side taillight socket and the vehicle wiring harness.
   • Ensure the connectors are fully inserted with locking tabs secure.

4. Route the Wiring:

   • Route the T-Connector end with the green wire and the 4-flat connector down through the opening between the vehicle bumper and body.
   • Route the green wire across to the passenger side and up through the opening, avoiding hot pipes, heat shields, or any other areas that could pinch or damage the wire.
   • Repeat step 3 for the passenger’s side using the green wire.

5. Power Connection:

   • Disconnect the vehicle’s negative (-) battery cable.
   • Cut the yellow fuse holder wire and attach the ring terminal. Secure it to the vehicle’s positive (+) battery cable.
   • Connect the other end of the fuse holder to the black 12-gauge wire using the supplied yellow butt connector.

6. Route Power Wire:

   • Route the black 12-gauge wire from the front of the vehicle along the frame rail to the rear driver’s side, avoiding hot pipes, heat shields, and other potential hazards.

7. Connect Power Wire:

   • Locate the opening between the rear bumper and body. Route the black wire through the opening and attach it to the red wire from the T-Connector black box using the supplied yellow butt connector.

8. Finalize Power:

   • Reconnect the vehicle’s negative (-) battery cable.
   • Install the 10-amp fuse into the fuse holder.

9. Secure Wiring and Black Box:

   • Secure all loose wiring. Clean a flat surface behind the driver’s side taillight assembly using a mixture of rubbing alcohol and water.
   • Mount the T-Connector black box using the provided double-sided tape.

10. Reinstall Components:

    • Reinstall the taillight housing assemblies, positioning the wiring harness between the housing and the vehicle body.
    • Secure the remainder of the T-Connector harness under the bumper with the provided cable ties.

11. Testing and Final Steps:

    • Test the installation with a test light or trailer.
    • Mount the 4-flat connector in a suitable location under the vehicle. Bracket not included.

    Specifications:

    • Max. stop/turn light: 1 per side (2.1 amps).
    • Max. tail lights: (4.2 amps).

Hardware List:

• T-Connector adapter.
• Yellow fuse holder with 10-amp fuse.
• Eyelet and screw.
• Double-sided tape.
• Cable ties.

Safety Notes:

• Ensure all connections are secure to avoid circuit overload.
• Test thoroughly after installation to confirm functionality.

Manufacturer Notes:

• Follow all warnings and installation instructions provided.
• Use a test light or trailer to confirm proper installation.
• Refer to the vehicle owner’s manual for additional details.

Installation Instructions for T-Connector Adapter

Part Numbers:

• 118390

Wiring Access Location:

• Rear taillight assemblies and under the vehicle near the bumper.

Tools Required:

• Trim panel remover
• Wire crimpers
• Wire cutters
• Pliers

Step-by-Step Instructions:

1. Access Taillight Wiring:

   • Open the tailgate and remove the vehicle’s right-side taillight assembly by removing the two clips holding it in place.
   • Carefully pry the housing away from the vehicle, ensuring the alignment tabs are not broken.
   • Repeat the process for the left-side taillight assembly.

2. Disconnect Wiring Harness:

   • Slide the red locking tab on the vehicle wiring harness connectors to the unlocked position.
   • Disconnect the wiring harness from both taillight sockets.

3. Install T-Connector:

   • Plug the T-Connector end with the yellow wire between the driver’s side taillight socket and the vehicle wiring harness.
   • Ensure the connectors are fully inserted with locking tabs secure.

4. Route the Wiring:

   • Route the T-Connector end with the green wire and the 4-flat connector down through the opening between the vehicle bumper and body.
   • Route the green wire across to the passenger side and up through the opening, avoiding hot pipes, heat shields, or any other areas that could pinch or damage the wire.
   • Repeat step 3 for the passenger’s side using the green wire.

5. Power Connection:

   • Disconnect the vehicle’s negative (-) battery cable.
   • Cut the yellow fuse holder wire and attach the ring terminal. Secure it to the vehicle’s positive (+) battery cable.
   • Connect the other end of the fuse holder to the black 12-gauge wire using the supplied yellow butt connector.

6. Route Power Wire:

   • Route the black 12-gauge wire from the front of the vehicle along the frame rail to the rear driver’s side, avoiding hot pipes, heat shields, and other potential hazards.

7. Connect Power Wire:

   • Locate the opening between the rear bumper and body. Route the black wire through the opening and attach it to the red wire from the T-Connector black box using the supplied yellow butt connector.

8. Finalize Power:

   • Reconnect the vehicle’s negative (-) battery cable.
   • Install the 10-amp fuse into the fuse holder.

9. Secure Wiring and Black Box:

   • Secure all loose wiring. Clean a flat surface behind the driver’s side taillight assembly using a mixture of rubbing alcohol and water.
   • Mount the T-Connector black box using the provided double-sided tape.

10. Reinstall Components:

    • Reinstall the taillight housing assemblies, positioning the wiring harness between the housing and the vehicle body.
    • Secure the remainder of the T-Connector harness under the bumper with the provided cable ties.

11. Testing and Final Steps:

    • Test the installation with a test light or trailer to verify:
      • Left Turn Signal
      • Right Turn Signal
      • Brake Lights
      • Running Lights
    • Mount the 4-flat connector in a suitable location under the vehicle. (Bracket not included.)

Specifications:

• Max Stop/Turn Light: 2.1 amps per side
• Max Tail Lights: 4.2 amps

Hardware List:

• T-Connector adapter
• Yellow fuse holder with 10-amp fuse
• Eyelet and screw
• Double-sided tape
• Cable ties

Safety Notes:

• Ensure all connections are secure to avoid circuit overload.
• Test thoroughly after installation to confirm functionality.
• Periodically inspect the wiring harness for wear or damage.

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.