Installation Instructions for RAM 1500

Part Numbers:

• 41948

Wiring Access Location:

• PU3

Tools Required:

• Wrenches: 3/4", 21mm
• Drill Bits: None

Step-by-Step Instructions:

1. Remove Existing Bolts:

   • Remove the existing M14 bolts from each cross member bracket.

2. Prepare Fasteners:

   • Feed a pull wire through the vehicle cross member. Attach a block and carriage bolt to the pull wire and pull them through the vehicle cross member into position as shown in the diagram.

3. Fishwire Fasteners:

   • Fishwire blocks and carriage bolts through the frame rails into the existing holes in the vehicle.

4. Raise Hitch:

   • Lift the hitch into position.

5. Install Rear Attachment:

   • Place a 1/2" flat washer between the frame rail and hitch for the rear attachment.

6. Reinstall Existing Bolts:

   • Reinstall the existing M14 bolts through the receiver and frame into the existing weld nuts.

7. Secure Fasteners:

   • Loosely install conical washers and nuts onto the carriage bolts.

8. Tighten All Fasteners:

   • Torque all fasteners to the following specifications:
     • M14 x 1.5 fasteners: 148 lb-ft (201 N*m)
     • 1/2"-13 GR5 fasteners: 75 lb-ft (102 N*m)

Torque Specifications:

• M14 x 1.5: 148 lb-ft (201 N*m)
• 1/2"-13 GR5: 75 lb-ft (102 N*m)

Hardware List:

• (4) Carriage Bolts, 1/2"-13 x 1.75" GR5
• (4) Hex Nuts, 1/2"-13
• (4) Conical Toothed Washers, 1/2"
• (2) Flat Washers, 1/2"
• (4) Blocks, 1/4" x 1" x 3"
• (4) Pull Wires, 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 vehicle's body to prevent water or exhaust fumes from entering.
• Replace any damaged hitch or ball immediately.
• Always wear eye protection and observe 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: 12,000 lb (5,448 kg)
  • Max Tongue Weight: 1,500 lb (681 kg)
• Weight Distributing:
  • Max Gross Trailer Weight: 15,000 lb (6,810 kg)
  • Max Tongue Weight: 1,500 lb (681 kg)

Additional Notes:

• Removal of the spare tire will make installation easier.
• This product complies with V.E.S.C. Regulation V-5 and SAE J684 safety standards.

Installation Instructions for Pickup Trucks (1500 Model)

Part Numbers:

• 41948

Wiring Access Location:

• PU3

Tools Required:

• Wrenches: 3/4", 21mm
• Drill Bits: None

Step-by-Step Instructions:

1. Remove Existing Bolts:

   • Remove the existing M14 bolts from each cross member bracket.

2. Prepare Fasteners:

   • Feed a pull wire through the vehicle cross member. Attach a block and carriage bolt to the pull wire and pull them through the vehicle cross member into position as shown in the diagram.

3. Fishwire Fasteners:

   • Fishwire blocks and carriage bolts through the frame rails into the existing holes in the vehicle.

4. Raise Hitch:

   • Lift the hitch into position.

5. Install Rear Attachment:

   • Place a 1/2" flat washer between the frame rail and hitch for the rear attachment.

6. Reinstall Existing Bolts:

   • Reinstall the existing M14 bolts through the receiver and frame into the existing weld nuts.

7. Secure Fasteners:

   • Loosely install conical washers and nuts onto the carriage bolts.

8. Tighten All Fasteners:

   • Torque all fasteners to the following specifications:
     • M14 x 1.5 fasteners: 148 lb-ft (201 N*m)
     • 1/2"-13 GR5 fasteners: 75 lb-ft (102 N*m)

Torque Specifications:

• M14 x 1.5: 148 lb-ft (201 N*m)
• 1/2"-13 GR5: 75 lb-ft (102 N*m)

Hardware List:

• (4) Carriage Bolts, 1/2"-13 x 1.75" GR5
• (4) Hex Nuts, 1/2"-13
• (4) Conical Toothed Washers, 1/2"
• (2) Flat Washers, 1/2"
• (4) Blocks, 1/4" x 1" x 3"
• (4) Pull Wires, 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 vehicle's body to prevent water or exhaust fumes from entering.
• Replace any damaged hitch or ball immediately.
• Always wear eye protection and observe 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: 12,000 lb (5,448 kg)
  • Max Tongue Weight: 1,500 lb (681 kg)
• Weight Distributing:
  • Max Gross Trailer Weight: 15,000 lb (6,810 kg)
  • Max Tongue Weight: 1,500 lb (681 kg)

Additional Notes:

• Removal of the spare tire will make installation easier.
• This product complies with V.E.S.C. Regulation V-5 and SAE J684 safety standards.

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 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 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