Installation Instructions for Dodge Sprinter, Mercedes Sprinter, and Freightliner Sprinter (with Factory Step Bumper)

Part Numbers:

• 44591
• 75601
• 87456

Tools Required:

• Wrenches: 18mm, 19mm
• Drill Bits: None

Wiring Access Location:

• SUV1, SUV2

Step-by-Step Instructions:

1. Prepare Bumper Mounting Bolts:

   • Remove all nuts from the existing bumper mounting bolts (3 per side). Do not remove the bolts yet.
   • If the bumper mounting bolts are pointing inboard, turn each bolt one at a time so they point outboard, ensuring the bolt heads are flush with the outboard side of the frame rails.
   • Note: Turning bolts one at a time prevents the bumper from falling.

2. Position the Hitch:

   • Raise the hitch into position.
   • Push the bumper mounting bolts the rest of the way through the hitch brackets.

3. Secure Hitch with Fasteners:

   • Reinstall the flange nuts removed in Step 1.
   • Install the additional bolts as shown in the diagram:
     • Insert M12 bolts, lock washers, spacers, and nuts on both sides.

4. Tighten Fasteners:

   • Use a torque wrench to tighten all M12 fasteners to 68 lb-ft (92 N·m).

Hardware List:

• (2) M12 x 1.75 x 120mm CL8.8 Hex Bolts
• (2) 1/2" Lock Washers
• (2) 7/16" x 1" x 2" Spacers
• (2) M12 x 1.75 Hex Nuts

Safety Notes:

• Frequently check the hitch 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.
• Always follow 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 Carrying (Ball Mount): Max Trailer Weight 5,000 lbs (2,270 kg), Max Tongue Weight 500 lbs (227 kg).
  • Weight Distributing: Max Trailer Weight 7,500 lbs (3,405 kg), Max Tongue Weight 750 lbs (341 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.

Additional Note:

• This hitch will not fit vehicles with a 30-3/8" frame width measured outside-to-outside.

Installation Instructions for Vehicles (Generic)
(With Factory Step Bumper)

Part Numbers:

• 44591
• 75601
• 87456

Tools Required:

• Wrenches: 18mm, 19mm
• Drill Bits: None

Wiring Access Location:

• SUV1, SUV2

Step-by-Step Instructions:

1. Prepare Bumper Mounting Bolts:

   • Remove all nuts from the existing bumper mounting bolts (3 per side). Do not remove the bolts yet.
   • If the bumper mounting bolts are pointing inboard, turn each bolt one at a time so they point outboard, ensuring the bolt heads are flush with the outboard side of the frame rails.
   • Note: Turning bolts one at a time prevents the bumper from falling.

2. Position the Hitch:

   • Raise the hitch into position.
   • Push the bumper mounting bolts the rest of the way through the hitch brackets.

3. Secure Hitch with Fasteners:

   • Reinstall the flange nuts removed in Step 1.
   • Install the additional bolts as shown in the diagram:
     • Insert M12 bolts, lock washers, spacers, and nuts on both sides.

4. Tighten Fasteners:

   • Use a torque wrench to tighten all M12 fasteners to 68 lb-ft (92 N·m).

Hardware List:

• (2) M12 x 1.75 x 120mm CL8.8 Hex Bolts
• (2) 1/2" Lock Washers
• (2) 7/16" x 1" x 2" Spacers
• (2) M12 x 1.75 Hex Nuts

Safety Notes:

• Frequently check the hitch 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.
• Always follow safety precautions when working beneath the vehicle, and wear eye protection.
• Do not cut access or attachment holes with a torch.

Warranty Information:

• For complete warranty instructions, please download the full installation PDF.

Specifications:

• Hitch Type and Weight Ratings:
  • Weight Carrying (Ball Mount): Max Trailer Weight 5,000 lbs (2,270 kg), Max Tongue Weight 500 lbs (227 kg).
  • Weight Distributing: Max Trailer Weight 7,500 lbs (3,405 kg), Max Tongue Weight 750 lbs (341 kg).
• Complies with safety specifications and requirements for connecting devices and towing systems.

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.

Additional Note:

• This hitch will not fit vehicles with a 30-3/8" frame width measured outside-to-outside.

Installation Instructions for T-Connector Adapter for Dodge Sprinter, Mercedes Sprinter and Freightliner Sprinter

Part Numbers:

• 118650

Tools Required:

• Trim Panel Remover
• 10mm Socket & Ratchet or Wrench
• Drill (3/32” Drill Bit)
• 1/4” Socket
• Wire Crimpers
• Wire Cutters
• Phillips Head Screwdriver
• Test Probe
• Torx 25 and Torx 30 Drivers

Step-by-Step Instructions:

1. Prepare the Rear Area:

   • Open the rear doors and locate the plastic covers at the rear of the taillights on both sides.
   • Using a trim panel remover, carefully remove the three plastic covers on each side. The first cover exposes the taillight harness; the two upper covers assist with wire routing.

2. Locate the Taillight Wiring Harness:

   • On both the driver’s and passenger’s sides, locate the vehicle's taillight wiring harness.
   • Disconnect the connectors carefully to avoid breaking the locking tabs. Ensure all connector surfaces are clean and free of dirt.

3. Mount the Black Box:

   • Find a flat surface near the taillight area inside the vehicle.
   • Mount the T-One® T-Connector’s black box module to prevent damage or rattling.

4. Driver-Side T-Connector Installation:

   • Insert the T-One® T-Connector end with the yellow wire between the vehicle wiring connectors.
   • Ensure the connectors are fully inserted with locking tabs secured.

5. Route the Passenger-Side T-Connector:

   • Route the T-Connector end with the green wire through the inner channel to the roof area of the vehicle.
   • Follow the existing wiring and route the wire to the passenger side. Secure it using the provided cable ties, concealing the wire behind the plastic covers where possible.

6. Passenger-Side T-Connector Installation:

   • Route the wires down through the holes exposed earlier and repeat Step 4 for the passenger side using the green wire.

7. Ground the White Wire:

   • Locate a suitable grounding point near the connector on the driver’s side.
   • Clean the grounding area and drill a 3/32” hole. Secure the white wire using the provided eyelet and screw.

   Caution:

   • Verify what is behind any surface before drilling to avoid vehicle damage or personal injury.

8. Connect the Power Wire:

   • From inside the vehicle, connect the black 12-gauge wire to the black wire from the T-One® T-Connector black box using the supplied yellow butt connector.
   • Route the wire through the channel to the roof area and then forward toward the driver’s seat, concealing the wire behind plastic covers where possible. Secure with cable ties.

9. Route the Wire to the Battery:

   • Continue routing the wire behind the trim panel next to the driver’s seat and down to the floor of the vehicle.
   • Access the vehicle battery beneath the driver’s side floor area by removing the trim threshold, floor covering, and metal battery cover.

10. Battery Connection:

    • Disconnect the negative (-) battery cable.
    • Cut the yellow fuse holder wire and attach the ring terminal. Secure it to the positive (+) battery cable.
    • Connect the other end of the fuse holder to the black 12-gauge wire using the supplied yellow butt connector.
    • Reconnect the negative (-) battery cable and install the 15-amp fuse into the fuse holder.

11. Secure Wiring:

    • Use the provided cable ties to secure the remainder of the T-One® T-Connector harness, avoiding areas that could pinch, cut, or melt the wire.

12. Reassemble the Vehicle:

    • Replace the plastic covers, battery cover, floor coverings, and all other components removed during installation.

13. Test the Installation:

    • Verify functionality using a test light or trailer. Reset the vehicle’s electrical system by temporarily removing the key from the ignition.

    Specifications:

    • Max. stop/turn light: 1 per side (2.1 amps)
    • Max. tail lights: (5.6 amps)

Safety Notes:

• Overloading circuits can cause fires. Do not exceed the lower of the towing manufacturer’s rating or the unit specifications.
• Always follow safety precautions and wear safety glasses during installation.

Manufacturer Notes:

• Store the 4-flat connector in the rear cargo area when not in use.
• Refer to the vehicle owner’s manual for additional details.

Installation Instructions for T-Connector Adapter for Dodge Sprinter, Mercedes Sprinter and Freightliner Sprinter

Part Numbers:

• 118650

Tools Required:

• Trim Panel Remover
• 10mm Socket & Ratchet or Wrench
• Drill (3/32” Drill Bit)
• 1/4” Socket
• Wire Crimpers
• Wire Cutters
• Phillips Head Screwdriver
• Test Probe
• Torx 25 and Torx 30 Drivers

Step-by-Step Instructions:

1. Prepare the Rear Area:

   • Open the rear doors and locate the plastic covers at the rear of the taillights on both sides.
   • Using a trim panel remover, carefully remove the three plastic covers on each side. The first cover exposes the taillight harness; the two upper covers assist with wire routing.

2. Locate the Taillight Wiring Harness:

   • On both the driver’s and passenger’s sides, locate the vehicle's taillight wiring harness.
   • Disconnect the connectors carefully to avoid breaking the locking tabs. Ensure all connector surfaces are clean and free of dirt.

3. Mount the Black Box:

   • Find a flat surface near the taillight area inside the vehicle.
   • Mount the T-One® T-Connector’s black box module to prevent damage or rattling.

4. Driver-Side T-Connector Installation:

   • Insert the T-One® T-Connector end with the yellow wire between the vehicle wiring connectors.
   • Ensure the connectors are fully inserted with locking tabs secured.

5. Route the Passenger-Side T-Connector:

   • Route the T-Connector end with the green wire through the inner channel to the roof area of the vehicle.
   • Follow the existing wiring and route the wire to the passenger side. Secure it using the provided cable ties, concealing the wire behind the plastic covers where possible.

6. Passenger-Side T-Connector Installation:

   • Route the wires down through the holes exposed earlier and repeat Step 4 for the passenger side using the green wire.

7. Ground the White Wire:

   • Locate a suitable grounding point near the connector on the driver’s side.
   • Clean the grounding area and drill a 3/32” hole. Secure the white wire using the provided eyelet and screw.

   Caution:

   • Verify what is behind any surface before drilling to avoid vehicle damage or personal injury.

8. Connect the Power Wire:

   • From inside the vehicle, connect the black 12-gauge wire to the black wire from the T-One® black box using the supplied yellow butt connector.
   • Route the wire through the channel to the roof area and then forward toward the driver’s seat, concealing the wire behind plastic covers where possible. Secure with cable ties.

9. Route the Wire to the Battery:

   • Continue routing the wire behind the trim panel next to the driver’s seat and down to the floor of the vehicle.
   • Access the vehicle battery beneath the driver’s side floor area by removing the trim threshold, floor covering, and metal battery cover.

10. Battery Connection:

    • Disconnect the negative (-) battery cable.
    • Cut the yellow fuse holder wire and attach the ring terminal. Secure it to the positive (+) battery cable.
    • Connect the other end of the fuse holder to the black 12-gauge wire using the supplied yellow butt connector.
    • Reconnect the negative (-) battery cable and install the 15-amp fuse into the fuse holder.

11. Secure Wiring:

    • Use the provided cable ties to secure the remainder of the T-One® T-Connector harness, avoiding areas that could pinch, cut, or melt the wire.

12. Reassemble the Vehicle:

    • Replace the plastic covers, battery cover, floor coverings, and all other components removed during installation.

13. Test the Installation:

    • Verify functionality using a test light or trailer. Reset the vehicle’s electrical system by temporarily removing the key from the ignition.

Specifications:

• Max. stop/turn light: 1 per side (2.1 amps)
• Max. tail lights: (5.6 amps)

Safety Notes:

• Overloading circuits can cause fires. Do not exceed the lower of the towing manufacturer’s rating or the unit specifications.
• Always follow safety precautions and wear safety glasses during installation.

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.

Manufacturer Notes:

• Store the 4-flat connector in the rear cargo area when not in use.
• Refer to the vehicle owner’s manual for additional details.

Warranty Information:

For complete warranty instructions, please download the full installation PDF.