Installation Instructions for Ford Van (Full Size)
(Includes E-150, E-250, and E-350 Models with Factory Step Bumper)

Part Numbers:

• 75703
• 44652
• 87599

Tools Required:

• Wrenches: 3/4”, 7/8”
• Drill Bits: 1/2” (on some models)

Wiring Access Location:

• SUV1, SUV2

Step-by-Step Instructions:

1992 and Newer Models:

1. Prepare the Frame:

   • Locate the existing holes in the vehicle frame. On some models, use the forward hole in the hitch that lines up with existing frame holes.

2. Install Hitch:

   • Position the hitch on the vehicle, ensuring it lines up with the frame holes.
   • Install carriage bolts, blocks, flat washers, and conical toothed washers as shown in Figure 1.

3. Secure Fasteners:

   • Loosely install all bolts and blocks as necessary. Ensure proper alignment before tightening.

4. Tighten Bolts:

   • Torque all 1/2” GR5 fasteners to 75 lb-ft (102 N·m).

5. Optional Steps for Exhaust Modifications:

   • For vehicles with thin tip exhausts, modifications to the exhaust may be necessary.

Pre-1992 Models:

1. Install Adapter Kit (Part No. 2626, Sold Separately):

   • For E-350 and 124” wheelbase models, the adapter kit is required.

2. Modify Carbon Canister:

   • If present, relocate or modify the carbon canister to ensure clearance with the hitch bolts.

3. Install Hitch:

   • Position the hitch on the frame, drill additional holes if required (refer to Figure 3 and Figure 4).

4. Tighten Fasteners:

   • Torque all fasteners to the specified torque (75 lb-ft).

Hardware List:

• (6) 1/2”-13 x 1.75” GR5 Carriage Bolts
• (6) Blocks 1/4” x 1” x 2” (1097-002)
• (6) Conical Toothed Washers
• (6) 1/2”-13 Hex Nuts
• (4) Flat Washers (depending on configuration)

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 body panels to prevent water and exhaust fumes from entering.
• Replace any damaged hitch or ball immediately.
• 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 Distributing: Max Trailer Weight 10,000 lbs (4,536 kg), Max Tongue Weight 1,000 lbs (454 kg).
  • Weight Carrying (Ball Mount): Max Trailer Weight 6,000 lbs (2,721 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.

Additional Notes:

• Installation of the hitch may require relocation of the tailpipe or modifications to the carbon canister.
• Obtain approval before any drilling or cutting on the vehicle frame.

Installation Instructions

Part Numbers:

• 75703
• 44652
• 87599

Tools Required:

• Wrenches: 3/4”, 7/8”
• Drill Bits: 1/2” (on some models)

Wiring Access Location:

• SUV1, SUV2

Step-by-Step Instructions:

1992 and Newer Models:

1. Prepare the Frame:

   • Locate the existing holes in the vehicle frame. On some models, use the forward hole in the hitch that lines up with existing frame holes.

2. Install Hitch:

   • Position the hitch on the vehicle, ensuring it lines up with the frame holes.
   • Install carriage bolts, blocks, flat washers, and conical toothed washers as shown in Figure 1.

3. Secure Fasteners:

   • Loosely install all bolts and blocks as necessary. Ensure proper alignment before tightening.

4. Tighten Bolts:

   • Torque all 1/2” GR5 fasteners to 75 lb-ft (102 N·m).

5. Optional Steps for Exhaust Modifications:

   • For vehicles with thin tip exhausts, modifications to the exhaust may be necessary.

Pre-1992 Models:

1. Install Adapter Kit (Part No. 2626, Sold Separately):

   • For E-350 and 124” wheelbase models, the adapter kit is required.

2. Modify Carbon Canister:

   • If present, relocate or modify the carbon canister to ensure clearance with the hitch bolts.

3. Install Hitch:

   • Position the hitch on the frame, drill additional holes if required (refer to Figure 3 and Figure 4).

4. Tighten Fasteners:

   • Torque all fasteners to the specified torque (75 lb-ft).

Hardware List:

• (6) 1/2”-13 x 1.75” GR5 Carriage Bolts
• (6) Blocks 1/4” x 1” x 2” (1097-002)
• (6) Conical Toothed Washers
• (6) 1/2”-13 Hex Nuts
• (4) Flat Washers (depending on configuration)

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 body panels to prevent water and exhaust fumes from entering.
• Replace any damaged hitch or ball immediately.
• 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 Distributing: Max Trailer Weight 10,000 lbs (4,536 kg), Max Tongue Weight 1,000 lbs (454 kg).
  • Weight Carrying (Ball Mount): Max Trailer Weight 6,000 lbs (2,721 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.

Additional Notes:

• Installation of the hitch may require relocation of the tailpipe or modifications to the carbon canister.
• Obtain approval before any drilling or cutting on the vehicle frame.

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:

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