Installation Instructions for 1999–2007 Ford F250/350 Super Duty Trucks

Part Numbers:

• 75740
• 87618
• 44673

Wiring Access Location:

• PU1, PU2 (Standard)
• PU3 (2004 Heritage Model)

Tools Required:

• Wrenches: 3/4", 7/8"
• Drill Bits: None

Step-by-Step Instructions:

1. Lower the spare tire:

   • Lower the spare tire on all Super Duty trucks.
   • For Light Duty trucks with 16” or larger tires, lower the spare tire. It will be reinstalled or relocated after the hitch installation.
   • Note: 20” spare tires cannot be relocated under the truck.

2. Ensure a clear frame:

   • Check that no electrical wires or other obstructions are inside the truck frame.
   • Ensure bolts and blocks can sit flat on the bottom of the frame when tightened.

3. Install carriage bolts and blocks:

   • Insert the carriage bolts and blocks down through the truck frame as shown in Figure 1.
   • Carefully raise the hitch into position to avoid pushing the bolts back through the frame.
   • Loosely install flat washers, lock washers, and hex nuts onto the carriage bolts.
   • After ensuring that blocks and bolts sit flat, torque all bolts to 75 lb-ft (102 N*m).

4. Reinstall the spare tire:

   • Replace the spare tire. If necessary, relocate it to ensure proper fitment.

Hardware List:

• Qty (6): Carriage Bolt – 1/2"-13 x 1-3/4" Gr5
• Qty (6): Helical Lock Washer – 1/2"
• Qty (6): Block with Square Hole – 1/4" x 1-1/2" x 2"
• Qty (6): Hex Nut – 1/2"
• Qty (6): Flat Washer – 1/2"

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.
• Observe safety precautions when working beneath the vehicle and wear eye protection.
• Do not cut access or attachment holes with a torch.

Specifications:

• Hitch Type: Weight Distributing
  • Max Gross Trailer Weight: 10,000 lbs (4,540 kg)
  • Max Tongue Weight: 1,000 lbs (454 kg)
• Hitch Type: Weight Carrying (Ball Mount)
  • Max Gross Trailer Weight: 6,000 lbs (2,724 kg)
  • Max Tongue Weight: 900 lbs (408 kg)

Manufacturer Notes:

• 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

Part Numbers:

• 75740
• 87618
• 44673

Wiring Access Location:

• PU1, PU2 (Standard)
• PU3 (2004 Heritage Model)

Tools Required:

• Wrenches: 3/4", 7/8"
• Drill Bits: None

Step-by-Step Instructions:

1. Lower the spare tire:

   • Lower the spare tire on all Super Duty trucks.
   • For Light Duty trucks with 16” or larger tires, lower the spare tire. It will be reinstalled or relocated after the hitch installation.
   • Note: 20” spare tires cannot be relocated under the truck.

2. Ensure a clear frame:

   • Check that no electrical wires or other obstructions are inside the truck frame.
   • Ensure bolts and blocks can sit flat on the bottom of the frame when tightened.

3. Install carriage bolts and blocks:

   • Insert the carriage bolts and blocks down through the truck frame as shown in Figure 1.
   • Carefully raise the hitch into position to avoid pushing the bolts back through the frame.
   • Loosely install flat washers, lock washers, and hex nuts onto the carriage bolts.
   • After ensuring that blocks and bolts sit flat, torque all bolts to 75 lb-ft (102 N·m).

4. Reinstall the spare tire:

   • Replace the spare tire. If necessary, relocate it to ensure proper fitment.

Hardware List:

• Qty (6): Carriage Bolt – 1/2"-13 x 1-3/4" Gr5
• Qty (6): Helical Lock Washer – 1/2"
• Qty (6): Block with Square Hole – 1/4" x 1-1/2" x 2"
• Qty (6): Hex Nut – 1/2"
• Qty (6): Flat Washer – 1/2"

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.
• Observe safety precautions when working beneath the vehicle and wear eye protection.
• Do not cut access or attachment holes with a torch.

Specifications:

• Hitch Type: Weight Distributing
  • Max Gross Trailer Weight: 10,000 lbs (4,540 kg)
  • Max Tongue Weight: 1,000 lbs (454 kg)
• Hitch Type: Weight Carrying (Ball Mount)
  • Max Gross Trailer Weight: 6,000 lbs (2,724 kg)
  • Max Tongue Weight: 900 lbs (408 kg)

Manufacturer Notes:

• 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.

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