Installation Instructions for GMC & Chevrolet 2500HD/3500/3500HD Sierra & Silverado Trucks

Part Numbers:

• 41944
• 96944

Wiring Access Location:

• PU3

Tools Required:

• Wrenches: 13/16", 7/8", 18mm, 21mm, 22mm
• Drill Bits: None

Step-by-Step Instructions:

1. Remove Existing Bolts:

   • Remove M14 bolts from the bottom of each truck frame rail’s bumper bracket.
   • Return these bolts to the vehicle owner.

2. Position Hitch:

   • Lift the hitch into position, aligning the rearmost slots on the hitch under the existing weldnuts in the truck frame.

3. Install Rear M14 Bolts:

   • Install the new M14 bolts through lock washers, blocks, and the hitch into the weldnuts in the truck frame.

4. Remove Side Nuts and Bolt Plates:

   • Remove M12 nuts and bolt plates from the sides of the frame.
   • Retain these for reinstallation later.

5. Adjust Bumper Brace (2001–2007 Models):

   • Loosen the nuts at the bumper end of the bumper brace, allowing it to swing away.

6. Install Attachment Bars:

   • Place attachment bars as shown in the instructions and loosely bolt them to the hitch.
   • For 2001–2007 models, swing the brace back and secure it as shown.

7. Install Remaining Fasteners:

   • Install remaining fasteners through the existing large holes in the truck frame as shown.
   • Use thinner blocks (1/4" x 3") under the hitch and orient the holes in the blocks to ensure they lay flat against the hitch when tightened.

8. Tighten Fasteners:

   • Torque all M14 x 1.5 (fine-thread) fasteners to 148 lb-ft (201 N*m).
   • Torque all M12 fasteners to 92 lb-ft (125 N*m).
   • Torque all M14 x 2.0 (course-thread) fasteners to 148 lb-ft (201 N*m).

Torque Specifications:

• M14 x 1.5 (fine-thread): 148 lb-ft (201 N*m)
• M14 x 2.0 (course-thread): 148 lb-ft (201 N*m)
• M12 fasteners: 92 lb-ft (125 N*m)

Hardware List:

• (2) Hex Bolts, M14 x 1.5 x 45mm CL10.9
• (2) Hex Bolts, M14 x 2.0 x 60mm CL10.9
• (6) Hex Bolts, M12 x 1.75 x 45mm CL10.9
• (2) Spacer Blocks, 3/8" x 1-1/2" x 3"
• (2) Spacer Blocks, 1/4" x 1-1/2" x 3" (offset hole)
• (2) Spacer Blocks, 3/8" x 1-1/2" x 2"
• (10) Conical Washers, 1/2"
• (2) Lock Washers, 1/2"
• (2) Lock Washers, 9/16"
• (6) Nuts, M12 x 1.75 CL10
• (2) Nuts, M14 x 1.5 CL10.9
• (2) Nuts, M14 x 2.0 CL8

Safety Notes:

• Frequently check the hitch to ensure all fasteners and the ball are securely tightened.
• If the hitch is removed, plug all holes in the vehicle's frame 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 a vehicle.
• Do not cut access or attachment holes with a torch.

Specifications:

• Weight Carrying (Ball Mount):
  • Max Gross Trailer Weight: 13,000 lb (5,902 kg)
  • Max Tongue Weight: 1,950 lb (886 kg)
• Weight Distributing:
  • Max Gross Trailer Weight: 16,000 lb (7,264 kg)
  • Max Tongue Weight: 1,600 lb (726 kg)

Additional Notes:

• Complies with V.E.S.C. Regulation V-5 and SAE J684 safety standards.
• Ensure proper alignment and torque specifications are followed to maintain safety and performance.

Installation Instructions for Pickup Trucks (2500HD/3500/3500HD Models)

Part Numbers:

• 41944
• 96944

Wiring Access Location:

• PU3

Tools Required:

• Wrenches: 13/16", 7/8", 18mm, 21mm, 22mm
• Drill Bits: None

Step-by-Step Instructions:

1. Remove Existing Bolts:

   • Remove M14 bolts from the bottom of each truck frame rail’s bumper bracket.
   • Return these bolts to the vehicle owner.

2. Position Hitch:

   • Lift the hitch into position, aligning the rearmost slots on the hitch under the existing weldnuts in the truck frame.

3. Install Rear M14 Bolts:

   • Install the new M14 bolts through lock washers, blocks, and the hitch into the weldnuts in the truck frame.

4. Remove Side Nuts and Bolt Plates:

   • Remove M12 nuts and bolt plates from the sides of the frame.
   • Retain these for reinstallation later.

5. Adjust Bumper Brace (2001–2007 Models):

   • Loosen the nuts at the bumper end of the bumper brace, allowing it to swing away.

6. Install Attachment Bars:

   • Place attachment bars as shown in the instructions and loosely bolt them to the hitch.
   • For 2001–2007 models, swing the brace back and secure it as shown.

7. Install Remaining Fasteners:

   • Install remaining fasteners through the existing large holes in the truck frame as shown.
   • Use thinner blocks (1/4" x 3") under the hitch and orient the holes in the blocks to ensure they lay flat against the hitch when tightened.

8. Tighten Fasteners:

   • Torque all M14 x 1.5 (fine-thread) fasteners to 148 lb-ft (201 N*m).
   • Torque all M12 fasteners to 92 lb-ft (125 N*m).
   • Torque all M14 x 2.0 (course-thread) fasteners to 148 lb-ft (201 N*m).

Torque Specifications:

• M14 x 1.5 (fine-thread): 148 lb-ft (201 N*m)
• M14 x 2.0 (course-thread): 148 lb-ft (201 N*m)
• M12 fasteners: 92 lb-ft (125 N*m)

Hardware List:

• (2) Hex Bolts, M14 x 1.5 x 45mm CL10.9
• (2) Hex Bolts, M14 x 2.0 x 60mm CL10.9
• (6) Hex Bolts, M12 x 1.75 x 45mm CL10.9
• (2) Spacer Blocks, 3/8" x 1-1/2" x 3"
• (2) Spacer Blocks, 1/4" x 1-1/2" x 3" (offset hole)
• (2) Spacer Blocks, 3/8" x 1-1/2" x 2"
• (10) Conical Washers, 1/2"
• (2) Lock Washers, 1/2"
• (2) Lock Washers, 9/16"
• (6) Nuts, M12 x 1.75 CL10
• (2) Nuts, M14 x 1.5 CL10.9
• (2) Nuts, M14 x 2.0 CL8

Safety Notes:

• Frequently check the hitch to ensure all fasteners and the ball are securely tightened.
• If the hitch is removed, plug all holes in the vehicle's frame 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 a vehicle.
• Do not cut access or attachment holes with a torch.

Specifications:

• Weight Carrying (Ball Mount):
  • Max Gross Trailer Weight: 13,000 lb (5,902 kg)
  • Max Tongue Weight: 1,950 lb (886 kg)
• Weight Distributing:
  • Max Gross Trailer Weight: 16,000 lb (7,264 kg)
  • Max Tongue Weight: 1,600 lb (726 kg)

Additional Notes:

• This product complies with V.E.S.C. Regulation V-5 and SAE J684 safety standards.
• Ensure proper alignment and torque specifications are followed to maintain safety and performance.

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 7-Way Flat Pin Connector / 4-Flat Combo Adapter Harness

Part Numbers:

• 74682

Tools Required:

• Phillips Head Screwdriver
• Adjustable Wrench

Mounting Bracket Instructions:

1. Determine a suitable mounting point on the tow vehicle for the connector or use an existing mount. Ensure the trailer’s wire harness has sufficient length to reach this point.
2. Secure the mounting bracket on the rear of the tow vehicle or to the plate attached to the hitch cross tube using the self-tapping screws provided.
   • Caution: Do not drill into the hitch cross tube to avoid damage to the hitch or personal injury. Do not drill into any exposed surfaces. Refer to the hitch owner’s manual or instruction sheet for recommendations and limitations.

Socket Instructions:

1. Install the 7-way Blade Socket (connector) onto the mounting bracket using the screws and nuts provided.
2. Plug the OEM factory-equipped car-end socket harness into the 7-way Blade Car Socket.
3. Insert the 4-flat connector into the slot in the bracket.
4. Tighten all screws securely.

Safety Notes:

• All connections must be completed to ensure proper functionality. Test and verify the installation using a test light, circuit tester, or trailer.
• Warning: Overloading circuits can cause fires. DO NOT exceed the lower of the towing manufacturer’s rating or:
  • Max Right Turn, Left Turn, Stop, and Tail Light Circuits: 7.5 amps
  • Max (+) Battery, Reverse, and Electric Brake Circuits: 30 amps
• Consult the vehicle’s owner’s manual and instruction sheet for additional information. Additional fusing may be required.

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.

Warning: Improper use or failure to follow instructions may result in property damage, serious injury, or death. Always consult your vehicle and trailer manuals for compatibility and installation guidelines.