Installation Instructions for Hyundai Sonata (2011-Current) and Kia Optima (2011-Current)

Part Numbers:

• 24965
• 77965
• CQT24965

Tools Required:

• Ratchet
• Torque Wrench
• Safety Glasses
• Sockets: 10mm, 11/16", 12mm, 13mm
• 6” Socket Extension
• Phillips Screwdriver
• Flat Head Screwdriver
• Exhaust Removal Pliers
• Tape Measure
• Tin Snips
• Utility Knife
• Ratchet Strap or Bungee Cord
• Soapy Water or Lubricant

Step-by-Step Instructions:

1. Lower Mufflers:

   • Remove the rearmost rubber hangers and the rubber hanger near the rear axle using exhaust removal pliers.
   • Spray lubricant on hangers to ease removal.
   • Support the exhaust before removing hangers.

2. Remove Factory Muffler Hanger Brackets:

   • Remove two hex nuts per hanger bracket and return brackets and fasteners to the vehicle owner.

3. Remove Driver-Side Plastic Panel:

   • Remove and return the panel to the vehicle owner or trim it as specified in Figure 10.

4. Remove Rear Plastic Panel:

   • Remove the panel covering the space between the bumper fascia and trunk pan and return it to the vehicle owner.

5. Remove Heat Shields:

   • Remove 3–5 hex nuts per shield to detach.
   • Trim heat shields as required (see Figures 7–9) and reinstall them later.

6. Install Rear Fasteners:

   • Use the pull wires provided to install 7/16 x 1.50" carriage bolts and special washers through 7/8" holes in the frame, pulling them through 3/4" rearward holes.

7. Install Forward Fasteners:

   • Use the pull wires provided to install 7/16 x 1.25" carriage bolts and spacer blocks through the same 7/8" holes.

8. Reinstall Heat Shields:

   • Attach the trimmed heat shields using the original fasteners.

9. Raise Hitch into Position:

   • Attach 7/16" conical toothed washers and hex nuts to the forward bolts.
   • Use spacer blocks and flat washers if necessary to level the hitch with the vehicle frame.
   • Tighten all 7/16-14 fasteners to 50 lb-ft (68 N*m).

10. Trim Fascia:

    • Trim a small notch in the fascia at the rear edge of the hitch bracket as needed.

11. Raise Mufflers:

    • Reattach all rubber hangers removed earlier.

12. Reinstall Plastic Panels:

    • Reinstall the driver-side and rear panels if trimming was done.

Hardware List:

• (2) Carriage Bolt, 7/16-14 x 1.25" GR5
• (2) Carriage Bolt, 7/16-14 x 1.50" GR5
• (2) Special Washer, .109 x .88 x 2.0 (Part No. 1204)
• (2) Spacer Block, 3/16 x 1.50 x 2.00 (Part No. 04833001)
• (4) Conical Washer, 7/16 (Part No. 01292007)
• (4) Hex Nut, 7/16-14 GR2
• (4) Flat Washer, 7/16 (used as spacers on some models)
• (4) Pull Wire, 7/16

Safety Notes:

• Always wear safety glasses during installation.
• Check hitch and fasteners frequently to ensure they remain securely tightened.
• Replace any damaged hitch or ball immediately.
• Plug all removed holes to prevent water or exhaust fume entry.
• Do not exceed the vehicle manufacturer’s towing ratings:
  • Max Gross Trailer Weight: 2,000 lb (908 kg)
  • Max Tongue Weight: 200 lb (90.8 kg)

Specifications:

• Installation Time: 40 minutes
• Complies with SAE J684 and VESC Regulation V-5 standards.

Installation Instructions for Vehicle (2011-Current)

Part Numbers:

• 24965
• 77965
• CQT24965

Tools Required:

• Ratchet
• Torque Wrench
• Safety Glasses
• Sockets: 10mm, 11/16", 12mm, 13mm
• 6” Socket Extension
• Phillips Screwdriver
• Flat Head Screwdriver
• Exhaust Removal Pliers
• Tape Measure
• Tin Snips
• Utility Knife
• Ratchet Strap or Bungee Cord
• Soapy Water or Lubricant

Step-by-Step Instructions:

1. Lower Mufflers:

   • Remove the rearmost rubber hangers and the rubber hanger near the rear axle using exhaust removal pliers.
   • Spray lubricant on hangers to ease removal.
   • Support the exhaust before removing hangers.

2. Remove Factory Muffler Hanger Brackets:

   • Remove two hex nuts per hanger bracket and return brackets and fasteners to the vehicle owner.

3. Remove Driver-Side Plastic Panel:

   • Remove and return the panel to the vehicle owner or trim it as specified in Figure 10.

4. Remove Rear Plastic Panel:

   • Remove the panel covering the space between the bumper fascia and trunk pan and return it to the vehicle owner.

5. Remove Heat Shields:

   • Remove 3–5 hex nuts per shield to detach.
   • Trim heat shields as required (see Figures 7–9) and reinstall them later.

6. Install Rear Fasteners:

   • Use the pull wires provided to install 7/16 x 1.50" carriage bolts and special washers through 7/8" holes in the frame, pulling them through 3/4" rearward holes.

7. Install Forward Fasteners:

   • Use the pull wires provided to install 7/16 x 1.25" carriage bolts and spacer blocks through the same 7/8" holes.

8. Reinstall Heat Shields:

   • Attach the trimmed heat shields using the original fasteners.

9. Raise Hitch into Position:

   • Attach 7/16" conical toothed washers and hex nuts to the forward bolts.
   • Use spacer blocks and flat washers if necessary to level the hitch with the vehicle frame.
   • Tighten all 7/16-14 fasteners to 50 lb-ft (68 N*m).

10. Trim Fascia:

    • Trim a small notch in the fascia at the rear edge of the hitch bracket as needed.

11. Raise Mufflers:

    • Reattach all rubber hangers removed earlier.

12. Reinstall Plastic Panels:

    • Reinstall the driver-side and rear panels if trimming was done.

Hardware List:

• (2) Carriage Bolt, 7/16-14 x 1.25" GR5
• (2) Carriage Bolt, 7/16-14 x 1.50" GR5
• (2) Special Washer, .109 x .88 x 2.0 (Part No. 1204)
• (2) Spacer Block, 3/16 x 1.50 x 2.00 (Part No. 04833001)
• (4) Conical Washer, 7/16 (Part No. 01292007)
• (4) Hex Nut, 7/16-14 GR2
• (4) Flat Washer, 7/16 (used as spacers on some models)
• (4) Pull Wire, 7/16

Safety Notes:

• Always wear safety glasses during installation.
• Check hitch and fasteners frequently to ensure they remain securely tightened.
• Replace any damaged hitch or ball immediately.
• Plug all removed holes to prevent water or exhaust fume entry.
• Do not exceed the vehicle manufacturer’s towing ratings:
  • Max Gross Trailer Weight: 2,000 lb (908 kg)
  • Max Tongue Weight: 200 lb (90.8 kg)

Specifications:

• Installation Time: 40 minutes
• Complies with SAE J684 and VESC Regulation V-5 standards.

Additional Information:

• 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.

Warranty:

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