Installation Instructions for Chevrolet Cobalt, Pontiac G5, and Pontiac Pursuit (Canada Only)

Part Numbers:

• 77122
• 24745
• 60808

Wiring Access Location:

• PC1, PC2

Tools Required:

• Drill
• Pull Wire (Provided)
• Wrenches: 3/4"
• Drill Bits: 1/2"

Specifications:

• Max Gross Trailer Weight: 2,000 lb. (908 kg)
• Max Tongue Weight: 200 lb. (90.8 kg)
• Note: Do not exceed towing vehicle ratings.

Step-by-Step Instructions:

1. Lower Exhaust:

   • Detach the exhaust from the rubber isolator to create space for installation.

2. Drill Frame Rail and Reinforcement Bracket:

   • Locate the 3/8” hole in the frame reinforcement bracket welded to the frame rail.
   • Center punch and drill a 1/2” hole in the frame rail, enlarging the 3/8” hole in the frame reinforcement bracket to 1/2”. Repeat on both sides.

3. Fishwire Carriage Bolt and Spacer:

   • Use the fishwire to guide the spacer and carriage bolt through the access slot in the frame rail and down through the drilled hole. Create a kink in the pull wire for tight areas (as shown in Figure 3). Repeat for both sides.

4. Position Hitch:

   • Raise the hitch into position, taking care not to push the carriage bolts back into the frame.
   • Secure the hitch using conical washers and nuts.

5. Drill Holes in Impact Bar:

   • Ensure the hitch is centered on the vehicle.
   • Using the hitch as a template, drill two (2) 1/2” holes into the vehicle’s impact bar.

6. Install Carriage Bolts in Impact Bar:

   • On the driver’s side, install the carriage bolt and spacer from the open face of the impact bar and down through the hole drilled in Step 5. Secure with a lock washer and nut.
   • On the passenger’s side, fishwire the carriage bolt and spacer through the end of the impact bar and down through the hole drilled in Step 5. Secure with a lock washer and nut.

7. Tighten Fasteners:

   • Torque all 1/2”-13 GR5 fasteners to 75 Lb.-Ft. (102 N*M) using a torque wrench.

8. Reattach Exhaust:

   • Raise the exhaust back into position and reattach it to the rubber isolator.

Hardware List:

• (4) Carriage Bolts: 1/2”-13 x 1.75”
• (4) Spacers: 1/4” x 1” x 3”
• (2) Conical Washers: 1/2”
• (4) Hex Nuts: 1/2”-13
• (2) Lock Washers: 1/2”

Safety Notes:

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

Drawbar:

• Drawbar Kit: 3593
• Important: The drawbar must be used in the rise position only.

Compliance:

• This product complies with SAE J684, V.E.S.C. Regulation V-5, and the safety requirements of the State of New York.

Additional Notes:

• Does not fit Chevrolet Cobalt SS Coupe, Pontiac Pursuit GT, or Pontiac G5 GT models.

Installation Instructions for Chevrolet Cobalt, Pontiac G5, and Pontiac Pursuit (Canada Only)

Part Numbers:

• 77122
• 24745
• 60808

Wiring Access Location:

• PC1, PC2

Tools Required:

• Drill
• Pull Wire (Provided)
• Wrenches: 3/4"
• Drill Bits: 1/2"

Specifications:

• Max Gross Trailer Weight: 2,000 lb. (908 kg)
• Max Tongue Weight: 200 lb. (90.8 kg)
• Note: Do not exceed towing vehicle ratings.

Step-by-Step Instructions:

1. Lower Exhaust:

   • Detach the exhaust from the rubber isolator to create space for installation.

2. Drill Frame Rail and Reinforcement Bracket:

   • Locate the 3/8” hole in the frame reinforcement bracket welded to the frame rail.
   • Center punch and drill a 1/2” hole in the frame rail, enlarging the 3/8” hole in the frame reinforcement bracket to 1/2”. Repeat on both sides.

3. Fishwire Carriage Bolt and Spacer:

   • Use the fishwire to guide the spacer and carriage bolt through the access slot in the frame rail and down through the drilled hole. Create a kink in the pull wire for tight areas (as shown in Figure 3). Repeat for both sides.

4. Position Hitch:

   • Raise the hitch into position, taking care not to push the carriage bolts back into the frame.
   • Secure the hitch using conical washers and nuts.

5. Drill Holes in Impact Bar:

   • Ensure the hitch is centered on the vehicle.
   • Using the hitch as a template, drill two (2) 1/2” holes into the vehicle’s impact bar.

6. Install Carriage Bolts in Impact Bar:

   • On the driver’s side, install the carriage bolt and spacer from the open face of the impact bar and down through the hole drilled in Step 5. Secure with a lock washer and nut.
   • On the passenger’s side, fishwire the carriage bolt and spacer through the end of the impact bar and down through the hole drilled in Step 5. Secure with a lock washer and nut.

7. Tighten Fasteners:

   • Torque all 1/2”-13 GR5 fasteners to 75 Lb.-Ft. (102 N*M) using a torque wrench.

8. Reattach Exhaust:

   • Raise the exhaust back into position and reattach it to the rubber isolator.

Hardware List:

• (4) Carriage Bolts: 1/2”-13 x 1.75”
• (4) Spacers: 1/4” x 1” x 3”
• (2) Conical Washers: 1/2”
• (4) Hex Nuts: 1/2”-13
• (2) Lock Washers: 1/2”

Safety Notes:

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

Drawbar:

• Drawbar Kit: 3593
• Important: The drawbar must be used in the rise position only.

Compliance:

• This product complies with SAE J684, V.E.S.C. Regulation V-5, and the safety requirements of the State of New York.

Additional Notes:

• Does not fit Chevrolet Cobalt SS Coupe, Pontiac Pursuit GT, or Pontiac G5 GT models.

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:

24745 Rev. A 6/25/2014

Installation Instructions for T-Connector Adapter

Part Numbers:

• 118407

Tools Required:

• Drill with 3/32” Drill Bit
• Philips Head Screwdriver
• Trim Panel Remover

Step-by-Step Instructions:

1. Access the Rear Cargo Area:

   • Locate the vehicle wiring inside the rear cargo area by removing the wiring access panels on both sides.
   • Carefully remove the foam insulation padding on each side to access the taillight connection points.
   • Note: Use the top set of connection points for the T-Connector.

2. Driver’s Side Connection:

   • Beginning on the driver’s side, disconnect the vehicle’s wiring connectors carefully to avoid breaking the locking tabs.
   • Connect the T-Connector containing the yellow wire between the separated connectors.
   • Ensure the connectors are fully inserted, and the locking tabs are secure.

3. Passenger’s Side Connection:

   • Remove the cargo floor panel and the cargo tray by unscrewing the spare tire hold-down nut. Set the cargo tray aside.
   • Route the T-Connector containing the green wire behind and under the trim panel along the vehicle floor near the spare tire.
   • Continue routing the wire across the vehicle, behind the trim panel, and up to the wiring access area on the passenger’s side.
   • Repeat Step 2 for the passenger’s side using the T-Connector containing the green wire.

4. Ground the White Wire:

   • Locate a suitable grounding point near the T-Connector. Do not drill into the vehicle floor or bed.
   • Clean the area to remove dirt and rustproofing.
   • Drill a 3/32” hole and secure the white wire using the provided eyelet and screw.
   • Caution: Verify what is behind any surface before drilling to avoid vehicle damage or personal injury.

5. Secure the Wiring Harness:

   • Use the provided cable ties to secure the T-Connector harness to prevent damage or rattling.
   • Avoid areas that could pinch, cut, or melt the wire.

6. Reassemble the Vehicle:

   • Replace the foam insulation padding, wiring access panels, cargo tray, spare tire hold-down nut, and cargo floor panel removed during installation.
   • Store the 4-flat connector in the rear cargo area when not in use.

7. Test the Installation:

   • Test and verify the installation with a test light or trailer.
   • Ensure all connections are complete for the T-Connector to function properly.

   Specifications:

   • Max. stop/turn light: 7.5 amps per side
   • Max. tail lights: 7.5 amps

Safety Notes:

• Overloading circuits can cause fires. Do not exceed the lower of the vehicle manufacturer’s rating or the unit specifications.
• Refer to the vehicle owner’s manual and instruction sheet for additional guidance.

Manufacturer Notes:

• Follow all warnings and installation instructions provided.
• Store the 4-flat connector in the rear cargo area when not in use.

Installation Instructions for T-Connector Adapter

Part Numbers:

• 118407

Tools Required:

• Drill with 3/32” Drill Bit
• Philips Head Screwdriver
• Trim Panel Remover

Step-by-Step Instructions:

1. Access the Rear Cargo Area:

   • Locate the vehicle wiring inside the rear cargo area by removing the wiring access panels on both sides.
   • Carefully remove the foam insulation padding on each side to access the taillight connection points.
   • Note: Use the top set of connection points for the T-Connector.

2. Driver’s Side Connection:

   • Beginning on the driver’s side, disconnect the vehicle’s wiring connectors carefully to avoid breaking the locking tabs.
   • Connect the T-Connector containing the yellow wire between the separated connectors.
   • Ensure the connectors are fully inserted, and the locking tabs are secure.

3. Passenger’s Side Connection:

   • Remove the cargo floor panel and the cargo tray by unscrewing the spare tire hold-down nut. Set the cargo tray aside.
   • Route the T-Connector containing the green wire behind and under the trim panel along the vehicle floor near the spare tire.
   • Continue routing the wire across the vehicle, behind the trim panel, and up to the wiring access area on the passenger’s side.
   • Repeat Step 2 for the passenger’s side using the T-Connector containing the green wire.

4. Ground the White Wire:

   • Locate a suitable grounding point near the T-Connector. Do not drill into the vehicle floor or bed.
   • Clean the area to remove dirt and rustproofing.
   • Drill a 3/32” hole and secure the white wire using the provided eyelet and screw.
   • Caution: Verify what is behind any surface before drilling to avoid vehicle damage or personal injury.

5. Secure the Wiring Harness:

   • Use the provided cable ties to secure the T-Connector harness to prevent damage or rattling.
   • Avoid areas that could pinch, cut, or melt the wire.

6. Reassemble the Vehicle:

   • Replace the foam insulation padding, wiring access panels, cargo tray, spare tire hold-down nut, and cargo floor panel removed during installation.
   • Store the 4-flat connector in the rear cargo area when not in use.

7. Test the Installation:

   • Test and verify the installation with a test light or trailer.
   • Ensure all connections are complete for the T-Connector to function properly.

Specifications:

• Max. Stop/Turn Light: 7.5 amps per side
• Max. Tail Lights: 7.5 amps

Safety Notes:

• Overloading circuits can cause fires. Do not exceed the lower of the vehicle manufacturer’s rating or the unit specifications.
• Refer to the vehicle owner’s manual and instruction sheet for additional guidance.

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.

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.