Installation Instructions for 2022-Current Ford Maverick

Part Numbers:

• 76557
• 84557
• CQT76557

Tools Required:

• Ratchet
• Torque Wrench
• Safety Glasses
• Sockets: 7 mm, 19 mm, 11/16"
• Socket Extension
• Flat Head Screwdriver
• Die Grinder
• Soapy Water
• Exhaust Removal Pliers
• Wire Brush

Step-by-Step Instructions:

1. Lower Exhaust Muffler:

   • Use soapy water to lubricate the exhaust rubber hangers.
   • Using exhaust removal pliers, remove two rubber hangers.
   • Ensure the exhaust is properly supported before removing the hangers.

2. Remove Bottom Appearance Panel:

   • Using a 7 mm socket and a flat head screwdriver, remove eight screws and one rivet from the passenger-side bottom appearance panel.
   • Return two screws to the vehicle owner.

3. Remove Bolts:

   • Using a 19 mm socket, remove two M12 bolts from the bottom surface of the chassis on both sides of the vehicle.

4. Install Hitch:

   • Feed one carriage bolt and one spacer through the access hole using pull wires on both sides of the vehicle.
   • Leave pull wires attached while raising the hitch into position.
   • Feed the pull wires through the hitch bracket slot, then remove the pull wires.
   • Loosely install one 7/16" conical washer and one 7/16" hex nut on both sides.
   • Insert three spacers between the offset bracket tab and the mounting surface.
   • Loosely secure the hitch using one M12 bolt and one 1/2" conical washer on the driver side.
   • Install three M12 bolts and three 1/2" conical washers into the remaining holes.

5. Tighten Fasteners:

   • Tighten all M12 fasteners to 68 ft-lbs (92 N*m).
   • Tighten all 7/16" fasteners to 50 ft-lbs (68 N*m).

6. Trim Appearance Panel:

   • Using a die grinder, trim the bottom appearance panel as shown in the instructions.
   • Reinstall the appearance panel using six screws and one rivet removed earlier.

7. Reinstall Exhaust:

   • Reinstall the rubber hangers and exhaust muffler.

Hardware List:

• (2) Carriage Bolt 7/16"-14 x 2.00" GR5
• (2) Hex Nut 7/16"-14 GR2
• (2) Conical Washer 7/16"
• (2) Spacer 0.250" x 1.00" x 3.00"
• (2) Pull Wire 7/16"
• (1) Bolt M12 x 1.75 x 70 mm CL8.8
• (4) Conical Washer 1/2"
• (2) Spacer 0.250" x 1.50" x 3.00"
• (1) Spacer 0.375" x 1.50" x 3.00"
• (3) Bolt M12 x 1.75 x 40 mm CL8.8

Safety Notes:

• Always wear safety glasses during installation.
• Periodically check the hitch to ensure all fasteners and the ball are securely tightened.
• Replace any damaged hitch or ball immediately.
• Plug all holes in the trunk pan or body panels if the hitch is removed to prevent water or exhaust fumes from entering.
• Observe safety precautions when working beneath the vehicle.

Specifications:

• Weight Carrying Capacity: 4,500 lbs (2,043 kg) trailer weight, 675 lbs (306 kg) tongue weight.
• Weight Distributing Capacity: 4,500 lbs (2,043 kg) trailer weight, 675 lbs (306 kg).
• Product complies with V.E.S.C. Regulation V-5 and SAE J684.

Additional Notes:

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

Installation Instructions for T-One® T-Connector for Ford Maverick

Part Numbers:

• 118866

Tools Required:

• 8mm Socket & Ratchet or 8mm Wrench
• Drill (3/32” Drill Bit)
• Wire Crimpers
• Wire Cutters
• Phillips Head Screwdriver
• Test Probe

Step-by-Step Instructions:

1. Open the Tailgate:

   • Remove the 8mm bolts securing the taillight assemblies on both the driver’s and passenger’s sides.
   • Carefully remove the taillights, ensuring not to damage the locking tabs. Set the taillights aside.

2. Disconnect the Wiring Harness:

   • Disconnect the vehicle wiring harness from both taillight assemblies.
   • Ensure all connectors are clean and free of dirt.

3. Route the Driver-Side T-Connector:

   • Route the harness containing the yellow wire up through the opening between the bed side and frame into the driver’s side taillight pocket.
   • Use a fish wire to guide the harness through the taillight pocket and bed side for ease of installation.

4. Connect the Driver-Side T-Connector:

   • Insert the T-One® Connector end with the yellow wire between the driver-side wiring connectors.
   • Ensure all connector surfaces are clean and secure the locking tabs.

5. Mount the Black Box:

   • Underneath the vehicle, below the driver’s side taillight pocket, mount the T-One® Connector black box using the provided double-sided tape.
   • Ensure the epoxy side of the module faces downward to prevent water accumulation.

6. Ground the White Wire:

   • Locate a suitable grounding point near the black box, such as an existing ground stud.
   • Drill a 3/32” hole and secure the white wire using the provided eyelet and screw.
   • Clean the grounding area to remove dirt and rustproofing.

   Caution: Verify the area behind the surface before drilling to avoid damage or injury.

7. Route the Passenger-Side T-Connector:

   • Route the harness containing the green wire behind the rear bumper to the passenger side.
   • Guide the harness up through the opening between the bed side and frame into the passenger’s side taillight pocket.

8. Connect the Passenger-Side T-Connector:

   • Insert the T-One® Connector end with the green wire between the passenger-side wiring connectors.
   • Ensure all connector surfaces are clean and secure the locking tabs.

9. Route the Power Wire:

   • Disconnect the vehicle’s Negative (-) battery cable.
   • Remove the fuse from the provided yellow fuse holder.
   • Attach the ring terminal to the Positive (+) battery cable and secure it.
   • Connect the other end of the fuse holder to the black 12-gauge wire using the provided yellow butt connector.

10. Install the Power Wire:

    • Route the black 12-gauge wire along the vehicle’s frame rail to the engine compartment.
    • Avoid routing near hot pipes, heat shields, or areas that may pinch or damage the wire.

11. Connect the Power Wire to the Black Box:

    • Attach the black 12-gauge wire to the black power wire on the T-One® Connector black box using the provided yellow butt connector.

12. Reconnect the Battery and Test:

    • Reconnect the Negative (-) battery cable and insert the 15-amp fuse into the fuse holder.
    • Test the installation using a test light or trailer. Reset the vehicle’s electrical system by temporarily removing the key from the ignition.

13. Reassemble the Vehicle:

    • Reinstall the taillight assemblies, trim panels, and any other components removed during installation.
    • Ensure no wires are pinched or damaged.

14. Secure the Harness:

    • Use cable ties to secure any loose wires and mount the trailer tow harness in an accessible location using a bracket or electrical box.

Safety Notes:

• Overloading circuits can cause fires. Do not exceed stated product ratings.
• Always wear safety glasses and follow safety precautions during installation.

Manufacturer Notes:

• Refer to the vehicle owner’s manual and the instruction sheet for additional details.
• Store these instructions for future reference.
• Always follow warnings and instructions printed on the tow vehicle’s battery.

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.