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