Installation Instructions for Ford F350/450/550

Part Numbers:

• 45516
• 45716

Tools Required:

• Drill Bits: 1/2", 5/8", 3/4"
• Wrenches/Sockets: 15/16", 1-1/8"
• Ratchet
• Torque Wrench
• Clamps

Specifications:

• Weight Carrying Capacity: 12,000 lbs (5,443 kg) trailer weight, 1,200 lbs (544 kg) tongue weight.
• Weight Distributing Capacity: 14,000 lbs (6,350 kg) trailer weight, 1,700 lbs (771 kg) tongue weight.

Step-by-Step Instructions:

1. Clamp Hitch into Position:

   • Raise the hitch into position, aligning rivet clearance holes in the bracket with rivet heads in the bottom of the frame.
   • Ensure the hitch is flat against the frame and clamp it securely.

2. Drill Rear Attachment Holes:

   • Use the hitch as a template to drill two 3/4" holes in the frame (one per side).

3. Install 3/4" Fasteners:

   • Loosely install 3/4" hex bolts, flat washers, lock washers, and hex nuts through the frame and hitch.

4. Drill Forward Attachment Holes:

   • Use the hitch as a template to drill two 5/8" holes in the frame (one per side).

5. Install 5/8" Fasteners:

   • Loosely install 5/8" hex bolts, flat washers, lock washers, and hex nuts through the frame and hitch.

6. Tighten Fasteners:

   • Tighten all 5/8"-11 Grade 5 fasteners to 110 lb-ft (136 N*m).
   • Tighten all 3/4"-10 Grade 5 fasteners to 200 lb-ft (271 N*m).

7. Drill Side Attachment Holes:

   • Use the hitch as a template to drill four 1/2" holes into the plates extending below the frame.

8. Install 1/2" Fasteners:

   • Loosely install 1/2" hex bolts, flat washers, lock washers, and hex nuts through the frame plates and hitch.
   • Tighten all 1/2"-13 Grade 5 fasteners to 70 lb-ft (95 N*m).

Hardware List:

• (4) Hex Bolt 1/2"-13 x 1.50" Grade 5
• (4) Flat Washer 1/2"
• (4) Lock Washer 1/2"
• (4) Hex Nut 1/2"-13
• (2) Hex Bolt 5/8"-11 x 2.00" Grade 5
• (4) Flat Washer 5/8"
• (2) Lock Washer 5/8"
• (2) Hex Nut 5/8"-11
• (2) Hex Bolt 3/4"-10 x 2.00" Grade 5
• (4) Flat Washer 3/4"
• (2) Lock Washer 3/4"
• (2) Hex Nut 3/4"-10

Safety Notes:

• Regularly inspect all fasteners and the hitch to ensure proper attachment.
• Replace any damaged hitch or fasteners immediately.
• Plug any holes in the trunk pan or body panels if the hitch is removed to prevent water or exhaust fumes from entering.
• Always wear safety glasses when working beneath the vehicle.
• Do not cut attachment holes with a torch.

Compliance:

• This product complies with V.E.S.C. Regulation V-5 and SAE J684 safety specifications for towing systems.

Additional Notes:

• Installation time for professional installers is approximately 60 minutes.
• For detailed photo instructions, visit the manufacturer's website or scan the QR code provided in the manual.

Installation Instructions for Gooseneck Mounting Kit

Part Numbers:

• 45516
• 45716

Tools Required:

• Drill Bits: 1/2", 5/8", 3/4"
• Wrenches/Sockets: 15/16", 1-1/8"
• Ratchet
• Torque Wrench
• Clamps

Specifications:

• Weight Carrying Capacity: 12,000 lbs (5,443 kg) trailer weight, 1,200 lbs (544 kg) tongue weight.
• Weight Distributing Capacity: 14,000 lbs (6,350 kg) trailer weight, 1,700 lbs (771 kg) tongue weight.

Step-by-Step Instructions:

1. Clamp Hitch into Position:

   • Raise the hitch into position, aligning rivet clearance holes in the bracket with rivet heads in the bottom of the frame.
   • Ensure the hitch is flat against the frame and clamp it securely.

2. Drill Rear Attachment Holes:

   • Use the hitch as a template to drill two 3/4" holes in the frame (one per side).

3. Install 3/4" Fasteners:

   • Loosely install 3/4" hex bolts, flat washers, lock washers, and hex nuts through the frame and hitch.

4. Drill Forward Attachment Holes:

   • Use the hitch as a template to drill two 5/8" holes in the frame (one per side).

5. Install 5/8" Fasteners:

   • Loosely install 5/8" hex bolts, flat washers, lock washers, and hex nuts through the frame and hitch.

6. Tighten Fasteners:

   • Tighten all 5/8"-11 Grade 5 fasteners to 110 lb-ft (136 N*m).
   • Tighten all 3/4"-10 Grade 5 fasteners to 200 lb-ft (271 N*m).

7. Drill Side Attachment Holes:

   • Use the hitch as a template to drill four 1/2" holes into the plates extending below the frame.

8. Install 1/2" Fasteners:

   • Loosely install 1/2" hex bolts, flat washers, lock washers, and hex nuts through the frame plates and hitch.
   • Tighten all 1/2"-13 Grade 5 fasteners to 70 lb-ft (95 N*m).

Hardware List:

• (4) Hex Bolt 1/2"-13 x 1.50" Grade 5
• (4) Flat Washer 1/2"
• (4) Lock Washer 1/2"
• (4) Hex Nut 1/2"-13
• (2) Hex Bolt 5/8"-11 x 2.00" Grade 5
• (4) Flat Washer 5/8"
• (2) Lock Washer 5/8"
• (2) Hex Nut 5/8"-11
• (2) Hex Bolt 3/4"-10 x 2.00" Grade 5
• (4) Flat Washer 3/4"
• (2) Lock Washer 3/4"
• (2) Hex Nut 3/4"-10

Safety Notes:

• Regularly inspect all fasteners and the hitch to ensure proper attachment.
• Replace any damaged hitch or fasteners immediately.
• Plug any holes in the trunk pan or body panels if the hitch is removed to prevent water or exhaust fumes from entering.
• Always wear safety glasses when working beneath the vehicle.
• Do not cut attachment holes with a torch.

Compliance:

• This product complies with V.E.S.C. Regulation V-5 and SAE J684 safety specifications for towing systems.

Additional Notes:

• Installation time for professional installers is approximately 60 minutes.
• For detailed photo instructions, visit the manufacturer's website or scan the QR code provided in the manual.

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

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.

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

Installation Instructions for 4-Way to 7-Way Adapter and Brake Control Wiring

Tools Required:

• Phillips Head Screwdriver
• Drill with 3/32" Drill Bit
• 10mm Socket & Ratchet or Wrench
• Wire Crimpers
• Wire Cutters
• Test Light or Multimeter
• Cable Ties

Part 1: Install the 4-Way to 7-Way Adapter

Step-by-Step Instructions:

1. Mount the Adapter:

   • Choose a suitable mounting point on the vehicle, typically near the hitch.
   • Use the provided bracket and screws to secure the adapter.

2. Connect the 4-Flat Plug:

   • Plug the 4-flat connector on the adapter into the existing 4-flat plug on the vehicle.
   • This connection enables tail lights, left turn, and right turn signals.

3. Ground the Adapter:

   • Locate a clean, solid grounding point near the adapter.
   • Drill a 3/32" hole if necessary and secure the white ground wire from the adapter using the provided screw and eyelet.

4. Leave Additional Wires Disconnected:

   • The following wires will remain disconnected until Part 2:
     • Black Wire: Power from the battery.
     • Blue Wire: Brake control output.
     • Yellow Wire: Reverse light (optional; leave disconnected unless needed).

5. Test Initial Connection:

   • Use a test light or trailer to verify functionality of the 4-way connections (tail lights, turn signals).

Part 2: Install Brake Control Wiring

Step-by-Step Instructions:

1. Mount Circuit Breakers:

   • Install two 30A circuit breakers on the firewall or another suitable location near the battery.
   • Use self-tapping screws to mount them securely.

2. Route Power Wires:

   • Connect the black 12-gauge wire from the 7-way adapter to the auxiliary side of one circuit breaker (this powers the 7-way socket).
   • Run a heavy-gauge wire from the battery's positive terminal to the battery side of this circuit breaker, using a ring terminal.
   • Run another heavy-gauge wire from the battery's positive terminal to the auxiliary side of the second circuit breaker (for the brake controller).

3. Install the Brake Controller:

   • Mount the brake controller under the dash on a firm surface.
   • Use the following connections:
     • Red Wire: Connect to the cold side of the brake switch (active only when the brake pedal is pressed).
     • Blue Wire: Connect to the blue wire on the 7-way adapter for trailer brakes.
     • White Wire: Connect to a solid ground point on the vehicle body.
     • Black Wire: Connect to the auxiliary side of the second 30A circuit breaker (provides power to the brake controller).

4. Optional: Connect Reverse Light Circuit:

   • If the trailer has a reverse light circuit, connect the yellow wire from the 7-way adapter to the vehicle’s reverse light circuit.

5. Reconnect the Battery:

   • Reattach the negative battery cable and ensure all connections are secure.
   • Insert the fuses into both circuit breakers.

6. Secure All Wires:

   • Use cable ties to secure all loose wires and prevent damage or rattling.

7. Test the System:

   • Verify functionality of all circuits (running lights, turn signals, brake lights, and brake controller output).
   • If applicable, test the reverse light circuit.

Notes:

• Most installations will only require connecting the black and blue wires from the 7-way adapter.
• Leave the yellow wire disconnected unless the trailer has a reverse light or surge brake lockout circuit.
• Always adhere to safety guidelines and verify all connections before use.

Warning: Incorrect wiring can cause damage to the vehicle or trailer. Test all connections carefully before use.

Installation Instructions for 4-Way to 7-Way Adapter and Brake Control Wiring

Tools Required:

• Phillips Head Screwdriver
• Drill with 3/32" Drill Bit
• 10mm Socket & Ratchet or Wrench
• Wire Crimpers
• Wire Cutters
• Test Light or Multimeter
• Cable Ties

Part 1: Install the 4-Way to 7-Way Adapter

Step-by-Step Instructions:

1. Mount the Adapter:

   • Choose a suitable mounting point on the vehicle, typically near the hitch.
   • Use the provided bracket and screws to secure the adapter.

2. Connect the 4-Flat Plug:

   • Plug the 4-flat connector on the adapter into the existing 4-flat plug on the vehicle.
   • This connection enables tail lights, left turn, and right turn signals.

3. Ground the Adapter:

   • Locate a clean, solid grounding point near the adapter.
   • Drill a 3/32" hole if necessary and secure the white ground wire from the adapter using the provided screw and eyelet.

4. Leave Additional Wires Disconnected:

   • The following wires will remain disconnected until Part 2:
     • Black Wire: Power from the battery.
     • Blue Wire: Brake control output.
     • Yellow Wire: Reverse light (optional; leave disconnected unless needed).

5. Test Initial Connection:

   • Use a test light or trailer to verify functionality of the 4-way connections (tail lights, turn signals).

Part 2: Install Brake Control Wiring

Step-by-Step Instructions:

1. Mount Circuit Breakers:

   • Install two 30A circuit breakers on the firewall or another suitable location near the battery.
   • Use self-tapping screws to mount them securely.

2. Route Power Wires:

   • Connect the black 12-gauge wire from the 7-way adapter to the auxiliary side of one circuit breaker (this powers the 7-way socket).
   • Run a heavy-gauge wire from the battery's positive terminal to the battery side of this circuit breaker, using a ring terminal.
   • Run another heavy-gauge wire from the battery's positive terminal to the auxiliary side of the second circuit breaker (for the brake controller).

3. Install the Brake Controller:

   • Mount the brake controller under the dash on a firm surface.
   • Use the following connections:
     • Red Wire: Connect to the cold side of the brake switch (active only when the brake pedal is pressed).
     • Blue Wire: Connect to the blue wire on the 7-way adapter for trailer brakes.
     • White Wire: Connect to a solid ground point on the vehicle body.
     • Black Wire: Connect to the auxiliary side of the second 30A circuit breaker (provides power to the brake controller).

4. Optional: Connect Reverse Light Circuit:

   • If the trailer has a reverse light circuit, connect the yellow wire from the 7-way adapter to the vehicle’s reverse light circuit.

5. Reconnect the Battery:

   • Reattach the negative battery cable and ensure all connections are secure.
   • Insert the fuses into both circuit breakers.

6. Secure All Wires:

   • Use cable ties to secure all loose wires and prevent damage or rattling.

7. Test the System:

   • Verify functionality of all circuits (running lights, turn signals, brake lights, and brake controller output).
   • If applicable, test the reverse light circuit.

Notes:

• Most installations will only require connecting the black and blue wires from the 7-way adapter.
• Leave the yellow wire disconnected unless the trailer has a reverse light or surge brake lockout circuit.
• Always adhere to safety guidelines and verify all connections before use.

Warning: Incorrect wiring can cause damage to the vehicle or trailer. Test all connections carefully before use.

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.