Installation Instructions for 2018-Current Hyundai Kona

Part Numbers:

• 76599
• 84599
• CQT76599

Tools Required:

• Ratchet
• Torque Wrench
• Safety Glasses
• Sockets: 10 mm, 11/16"
• 6-inch Socket Extension
• Flat Head Screwdriver
• Exhaust Removal Pliers
• Soapy Water

Step-by-Step Instructions:

1. Lower Muffler:

   • Remove the exhaust hanger rod from the rubber isolator on the driver side, passenger side, and forward side of the muffler using exhaust removal pliers.
   • Support the muffler to prevent damage during the installation.

2. Remove Passenger-Side Dust Panel:

   • Use a flat head screwdriver to remove two plastic rivets.
   • Use a 10 mm socket to remove one nut.
   • Return the dust panel to the vehicle owner.

3. Install Hitch:

   • Remove the rubber plugs from the frame access holes located forward of the mounting holes.
   • Use pull wires to feed the 7/16” carriage bolts and spacers through the access holes and out of the mounting holes on both sides.
   • Leave the pull wires attached and raise the hitch into position.
   • Feed the pull wires through the hitch bracket slots, slide the bolts through the mounting holes, and remove the pull wires.
   • Loosely install the conical washers (teeth side toward the hitch) and 7/16” hex nuts.

4. Tighten Fasteners:

   • Tighten all 7/16”-14 GR5 fasteners to 50 ft-lbs (68 N*m) using a torque wrench.

5. Reattach Exhaust:

   • Reattach the exhaust to the rubber isolators and reinsert the rubber plugs into the access holes.

Hardware List:

• (4) Carriage Bolt 7/16"-14 x 1.25" GR5
• (4) Spacer 0.109" x 0.88" x 2.00"
• (4) Conical Washer 7/16"
• (4) Hex Nut 7/16"-14 GR2
• (4) Pull Wire 7/16"

Safety Notes:

• Always wear safety glasses during installation.
• Periodically check that all fasteners and the hitch 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 all safety precautions when working beneath the vehicle.
• Do not cut access or attachment holes with a torch.

Specifications:

• Weight Carrying Capacity: 2,000 lbs (907 kg) trailer weight, 300 lbs (136 kg) tongue weight.
• Weight Distributing Capacity: Not applicable.
• Product complies with V.E.S.C. Regulation V-5 and SAE J684.

Additional Notes:

• Installation time for professional installers is approximately 35 minutes.
• For step-by-step photo instructions, scan the QR code provided in the manual or visit the website.

Installation Instructions for 2018-Current Hyundai Kona

Part Numbers:

• 76599
• 84599
• CQT76599

Tools Required:

• Ratchet
• Torque Wrench
• Safety Glasses
• Sockets: 10 mm, 11/16"
• 6-inch Socket Extension
• Flat Head Screwdriver
• Exhaust Removal Pliers
• Soapy Water

Step-by-Step Instructions:

1. Lower Muffler:

• Remove the exhaust hanger rod from the rubber isolator on the driver side, passenger side, and forward side of the muffler using exhaust removal pliers.
• Support the muffler to prevent damage during the installation.

2. Remove Passenger-Side Dust Panel:

• Use a flat head screwdriver to remove two plastic rivets.
• Use a 10 mm socket to remove one nut.
• Return the dust panel to the vehicle owner.

3. Install Hitch:

• Remove the rubber plugs from the frame access holes located forward of the mounting holes.
• Use pull wires to feed the 7/16” carriage bolts and spacers through the access holes and out of the mounting holes on both sides.
• Leave the pull wires attached and raise the hitch into position.
• Feed the pull wires through the hitch bracket slots, slide the bolts through the mounting holes, and remove the pull wires.
• Loosely install the conical washers (teeth side toward the hitch) and 7/16” hex nuts.

4. Tighten Fasteners:

• Use a torque wrench to tighten all 7/16”-14 GR5 fasteners to 50 ft-lbs (68 N*m).

5. Reattach Exhaust:

• Reattach the exhaust to the rubber isolators and reinsert the rubber plugs into the access holes.

Hardware List:

• (4) Carriage Bolt 7/16"-14 x 1.25" GR5
• (4) Spacer 0.109" x 0.88" x 2.00"
• (4) Conical Washer 7/16"
• (4) Hex Nut 7/16"-14 GR2
• (4) Pull Wire 7/16"

Safety Notes:

• Always wear safety glasses during installation.
• Periodically check that all fasteners and the hitch 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 all safety precautions when working beneath the vehicle.
• Do not cut access or attachment holes with a torch.

Specifications:

• Weight Carrying Capacity: 2,000 lbs (907 kg) trailer weight, 300 lbs (136 kg) tongue weight.
• Weight Distributing Capacity: Not applicable.
• Product complies with V.E.S.C. Regulation V-5 and SAE J684.

Additional Notes:

• 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 time for professional installers is approximately 35 minutes.
• For step-by-step photo instructions, scan the QR code provided in the manual or visit the website.

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 Information:

This product is covered under a limited warranty. For complete warranty instructions, please download the full installation PDF.

Installation Instructions for Modulite® HD Protector Vehicle Wiring

Part Number:

• 119148

Tools Required:

• Phillips Head #2 Screwdriver
• Wire Cutters
• Wire Strippers/Wire Crimpers
• Tester or Volt Meter
• Socket & Ratchet Set
• Drill with 3/32” Drill Bit
• Double-Sided Tape

Step-by-Step Instructions:

Tow Vehicle Inputs - Determination:

1. Disconnect and isolate the vehicle's negative battery terminal.
   • Warning: Read and follow all warnings and instructions on the tow vehicle's battery.
2. Splice the tow harness input wires to the vehicle as determined.
   • Caution: Use appropriate gauge wire splices. Blue taps are for 16-18 gauge wires only.

Harness Installation:

1. Determine the mounting location of the module and secure it using the double-sided tape provided.
   • Warning: Mount the module with the epoxy side pointed towards the ground to prevent water buildup.
2. Locate a suitable grounding point near the module, such as an existing ground stud, or drill a 3/32” hole to secure the white wire using the provided eyelet and screw.
   • Caution: Verify what is behind any surface before drilling to avoid damage or personal injury.
3. Route the power wire to the vehicle’s positive battery terminal. Use the provided fuse holder, butt connector, and ring terminal to connect to the battery.
   • Do not insert the 15 amp fuse yet.
   • Caution: Ensure the module is connected to a constant power source and avoid routing the wire near hot pipes, heat shields, fuel tanks, or pinch points.

Completion:

1. Secure the harness with cable ties provided to prevent damage or rattling.
2. Reconnect the vehicle's negative battery cable.
3. Insert the 15 amp fuse into the fuse holder and close the cap.
4. Test the installation using a test light or trailer. Check each function independently and in combination.

Hardware List:

• 8 × Cable Ties, 8.5”
• 1 × 15 AMP Fuse
• 2 × Ring Terminals
• 1 × Fuse Holder
• 2 × Yellow Butt Connectors
• 1 × Self-Tapping Screw
• 4 × Blue Taps
• 1 × Spade Terminal

Wiring Outputs:

• White Wire: Ground
• Brown Wire: Tail
• Yellow Wire: Left Turn/Brake
• Green Wire: Right Turn/Brake
• Red Wire: Stop (for 3-wire systems only)

Safety Notes:

• Always read and follow all warnings and instructions included with the product and the vehicle's manual.
• Do not exceed the manufacturer’s towing capacity or the product’s amperage ratings.
• Wear safety glasses and use all necessary safety precautions during installation.

Troubleshooting Guide:

• 4-Flat Not Functioning: Ensure input wires are correctly installed and repeat testing after removing the 15 amp fuse for 10 seconds.
• No Power to 4-Flat: Check the chassis ground and ensure the module is properly connected to a constant power source.

Specifications:

• Installation Time: Approximately 45 minutes
• Compatibility: Does not work with multiplex vehicles (BM, BT, or BTT). Use part numbers 119190 or 119250 for these systems.

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.

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.

For warranty information, please download the full installation PDF.