Installation Instructions for Dodge Sprinter, Mercedes Sprinter, and Freightliner Sprinter (with Factory Step Bumper)

Part Numbers:

• 44591
• 75601
• 87456

Tools Required:

• Wrenches: 18mm, 19mm
• Drill Bits: None

Wiring Access Location:

• SUV1, SUV2

Step-by-Step Instructions:

1. Prepare Bumper Mounting Bolts:

   • Remove all nuts from the existing bumper mounting bolts (3 per side). Do not remove the bolts yet.
   • If the bumper mounting bolts are pointing inboard, turn each bolt one at a time so they point outboard, ensuring the bolt heads are flush with the outboard side of the frame rails.
   • Note: Turning bolts one at a time prevents the bumper from falling.

2. Position the Hitch:

   • Raise the hitch into position.
   • Push the bumper mounting bolts the rest of the way through the hitch brackets.

3. Secure Hitch with Fasteners:

   • Reinstall the flange nuts removed in Step 1.
   • Install the additional bolts as shown in the diagram:
     • Insert M12 bolts, lock washers, spacers, and nuts on both sides.

4. Tighten Fasteners:

   • Use a torque wrench to tighten all M12 fasteners to 68 lb-ft (92 N·m).

Hardware List:

• (2) M12 x 1.75 x 120mm CL8.8 Hex Bolts
• (2) 1/2" Lock Washers
• (2) 7/16" x 1" x 2" Spacers
• (2) M12 x 1.75 Hex Nuts

Safety Notes:

• Frequently check the hitch to ensure all fasteners and the ball are properly tightened.
• If the hitch is removed, plug all holes in the trunk pan or other body panels to prevent water and exhaust fumes from entering.
• Replace any damaged hitch or ball immediately.
• Always follow safety precautions when working beneath the vehicle, and wear eye protection.
• Do not cut access or attachment holes with a torch.

Specifications:

• Hitch Type and Weight Ratings:
  • Weight Carrying (Ball Mount): Max Trailer Weight 5,000 lbs (2,270 kg), Max Tongue Weight 500 lbs (227 kg).
  • Weight Distributing: Max Trailer Weight 7,500 lbs (3,405 kg), Max Tongue Weight 750 lbs (341 kg).
• Complies with safety specifications and requirements for connecting devices and towing systems of the State of New York, V.E.S.C. Regulation V-5, and SAE J684.

Additional Note:

• This hitch will not fit vehicles with a 30-3/8" frame width measured outside-to-outside.

Installation Instructions for Vehicles (Generic)
(With Factory Step Bumper)

Part Numbers:

• 44591
• 75601
• 87456

Tools Required:

• Wrenches: 18mm, 19mm
• Drill Bits: None

Wiring Access Location:

• SUV1, SUV2

Step-by-Step Instructions:

1. Prepare Bumper Mounting Bolts:

   • Remove all nuts from the existing bumper mounting bolts (3 per side). Do not remove the bolts yet.
   • If the bumper mounting bolts are pointing inboard, turn each bolt one at a time so they point outboard, ensuring the bolt heads are flush with the outboard side of the frame rails.
   • Note: Turning bolts one at a time prevents the bumper from falling.

2. Position the Hitch:

   • Raise the hitch into position.
   • Push the bumper mounting bolts the rest of the way through the hitch brackets.

3. Secure Hitch with Fasteners:

   • Reinstall the flange nuts removed in Step 1.
   • Install the additional bolts as shown in the diagram:
     • Insert M12 bolts, lock washers, spacers, and nuts on both sides.

4. Tighten Fasteners:

   • Use a torque wrench to tighten all M12 fasteners to 68 lb-ft (92 N·m).

Hardware List:

• (2) M12 x 1.75 x 120mm CL8.8 Hex Bolts
• (2) 1/2" Lock Washers
• (2) 7/16" x 1" x 2" Spacers
• (2) M12 x 1.75 Hex Nuts

Safety Notes:

• Frequently check the hitch to ensure all fasteners and the ball are properly tightened.
• If the hitch is removed, plug all holes in the trunk pan or other body panels to prevent water and exhaust fumes from entering.
• Replace any damaged hitch or ball immediately.
• Always follow safety precautions when working beneath the vehicle, and wear eye protection.
• Do not cut access or attachment holes with a torch.

Warranty Information:

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

Specifications:

• Hitch Type and Weight Ratings:
  • Weight Carrying (Ball Mount): Max Trailer Weight 5,000 lbs (2,270 kg), Max Tongue Weight 500 lbs (227 kg).
  • Weight Distributing: Max Trailer Weight 7,500 lbs (3,405 kg), Max Tongue Weight 750 lbs (341 kg).
• Complies with safety specifications and requirements for connecting devices and towing 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.

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.

Additional Note:

• This hitch will not fit vehicles with a 30-3/8" frame width measured outside-to-outside.

Installation Instructions for T-One® T-Connector for Mercedes Sprinter

Part Numbers:

• 118649

Tools Required:

• Trim Panel Remover
• 10mm Socket & Ratchet or Wrench
• Drill (3/32” Drill Bit)
• 1/4” Socket
• Wire Crimpers
• Wire Cutters
• Phillips Head Screwdriver
• Test Probe
• Torx 25 Driver
• Torx 30 Driver

Step-by-Step Instructions:

1. Open Rear Doors and Access Taillights:

   • Locate the plastic covers that shield the rear taillights on each side of the vehicle.
   • Using a trim panel remover, carefully remove the three covers on each side. The first cover exposes the taillight harness; the upper covers assist with wire routing.

2. Disconnect the Wiring Harness:

   • On both sides, locate the vehicle’s taillight wiring harness.
   • Disconnect the harness connectors, ensuring the locking tabs remain intact.
   • Clean all connector surfaces to ensure proper connection.

3. Install the T-One® T-Connector Black Box:

   • Find a flat surface near the taillight area inside the vehicle.
   • Mount the black box module to prevent damage or rattling.

4. Connect the Driver-Side T-Connector:

   • Insert the T-Connector end with the yellow wire between the driver-side vehicle wiring connectors.
   • Ensure all connectors are fully inserted and locked securely.

5. Route the Passenger-Side T-Connector:

   • Route the T-Connector end with the green wire through the inner channel to the roof area of the vehicle.
   • Follow existing wiring across to the passenger side and conceal the wire behind plastic wire covers where possible.
   • Secure the wiring to existing harnesses using the provided cable ties.

6. Connect the Passenger-Side T-Connector:

   • Route the wires down through the openings exposed earlier.
   • Connect the T-Connector end with the green wire to the passenger-side wiring harness.

7. Ground the White Wire:

   • Locate a grounding point near the driver-side connector.
   • Clean the area to remove dirt and rustproofing.
   • Drill a 3/32” hole and secure the white wire with the provided eyelet and screw.

   Caution:

   • Verify the area behind before drilling to avoid damage or injury.

8. Connect the Power Wire:

   • From inside the vehicle, connect the black 12-gauge wire to the black wire from the T-One® black box using the yellow butt connector.
   • Route the black wire through the channel to the roof area, following existing wiring toward the driver's seat.
   • Conceal the wire behind plastic wire covers where possible.

9. Route the Wire to the Battery:

   • Continue routing the black wire behind the trim panel next to the driver's seat and along the vehicle floor.
   • Access the battery compartment beneath the driver-side floor.
   • Remove the screws holding the threshold and floor coverings, then expose the battery.

10. Connect to the Vehicle Battery:

    • Disconnect the negative (-) battery cable.
    • Attach the provided fuse holder to the positive (+) battery terminal using the provided ring terminal.
    • Connect the other end of the fuse holder to the black wire with the yellow butt connector.
    • Insert the 15-amp fuse into the fuse holder.

    Warning:

    • Follow all warnings and instructions for handling the vehicle battery.

11. Reconnect the Battery:

    • Reconnect the negative (-) battery cable.
    • Test the installation with a test light or trailer to ensure proper operation.

12. Secure and Reassemble:

    • Use cable ties to secure the remaining harness.
    • Replace all trim panels, covers, and components removed during installation, ensuring no wires are pinched or damaged.

13. Store the 4-Flat Connector:

    • Store the 4-flat connector in the vehicle's cargo area when not in use.

Specifications:

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

Safety Notes:

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

Manufacturer Notes:

• Refer to the vehicle owner’s manual and instruction sheet for additional details.
• Store these instructions for future reference.

Installation Instructions for T-One® T-Connector for Mercedes Sprinter

Part Numbers:

• 118649

Tools Required:

• Trim Panel Remover
• 10mm Socket & Ratchet or Wrench
• Drill (3/32” Drill Bit)
• 1/4” Socket
• Wire Crimpers
• Wire Cutters
• Phillips Head Screwdriver
• Test Probe
• Torx 25 Driver
• Torx 30 Driver

Step-by-Step Instructions:

1. Open Rear Doors and Access Taillights:

   • Locate the plastic covers that shield the rear taillights on each side of the vehicle.
   • Using a trim panel remover, carefully remove the three covers on each side. The first cover exposes the taillight harness; the upper covers assist with wire routing.

2. Disconnect the Wiring Harness:

   • On both sides, locate the vehicle’s taillight wiring harness.
   • Disconnect the harness connectors, ensuring the locking tabs remain intact.
   • Clean all connector surfaces to ensure proper connection.

3. Install the T-One® T-Connector Black Box:

   • Find a flat surface near the taillight area inside the vehicle.
   • Mount the black box module to prevent damage or rattling.

4. Connect the Driver-Side T-Connector:

   • Insert the T-Connector end with the yellow wire between the driver-side vehicle wiring connectors.
   • Ensure all connectors are fully inserted and locked securely.

5. Route the Passenger-Side T-Connector:

   • Route the T-Connector end with the green wire through the inner channel to the roof area of the vehicle.
   • Follow existing wiring across to the passenger side and conceal the wire behind plastic wire covers where possible.
   • Secure the wiring to existing harnesses using the provided cable ties.

6. Connect the Passenger-Side T-Connector:

   • Route the wires down through the openings exposed earlier.
   • Connect the T-Connector end with the green wire to the passenger-side wiring harness.

7. Ground the White Wire:

   • Locate a grounding point near the driver-side connector.
   • Clean the area to remove dirt and rustproofing.
   • Drill a 3/32” hole and secure the white wire with the provided eyelet and screw.

   Caution:

   • Verify the area behind before drilling to avoid damage or injury.

8. Connect the Power Wire:

   • From inside the vehicle, connect the black 12-gauge wire to the black wire from the T-One® black box using the yellow butt connector.
   • Route the black wire through the channel to the roof area, following existing wiring toward the driver's seat.
   • Conceal the wire behind plastic wire covers where possible.

9. Route the Wire to the Battery:

   • Continue routing the black wire behind the trim panel next to the driver's seat and along the vehicle floor.
   • Access the battery compartment beneath the driver-side floor.
   • Remove the screws holding the threshold and floor coverings, then expose the battery.

10. Connect to the Vehicle Battery:

    • Disconnect the negative (-) battery cable.
    • Attach the provided fuse holder to the positive (+) battery terminal using the provided ring terminal.
    • Connect the other end of the fuse holder to the black wire with the yellow butt connector.
    • Insert the 15-amp fuse into the fuse holder.

    Warning:

    • Follow all warnings and instructions for handling the vehicle battery.

11. Reconnect the Battery:

    • Reconnect the negative (-) battery cable.
    • Test the installation with a test light or trailer to ensure proper operation.

12. Secure and Reassemble:

    • Use cable ties to secure the remaining harness.
    • Replace all trim panels, covers, and components removed during installation, ensuring no wires are pinched or damaged.

13. Store the 4-Flat Connector:

    • Store the 4-flat connector in the vehicle's cargo area when not in use.

Specifications:

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

Safety Notes:

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

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.

Manufacturer Notes:

• Refer to the vehicle owner’s manual and instruction sheet for additional details.
• Store these instructions for future reference.

Warranty Information:

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

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.

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.

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.

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.

Installation and Operation Instructions for the P3 Electronic Brake Control

Specifications:

• Supports 2, 4, 6, and 8 brake applications.
• Utilizes proportional braking with an inertial sensor.

Tools Required:

• Drill with a 1/8" bit.
• Screwdriver or nut driver.
• Wire crimp tool.
• Probe-type circuit tester.

Safety Notes:

1. Avoid mounting or activating RF-generating devices (e.g., cell phones) within 12 inches of the brake control.
2. Always adhere to the vehicle's Gross Combined Weight Rating (GCWR).
3. Do not use the Boost feature during icy or slippery road conditions.
4. Disconnect the trailer plug before testing a breakaway switch to prevent damage.

Hardware List:

• P3 Brake Control Unit.
• Mounting bracket.
• Wiring harness.
• #8 x 3/8" self-tapping screws.

Installation Instructions:

Mounting the Brake Control:

1. Traditional Bracket Mount:

   • Secure the bracket to a solid surface using the provided screws.
   • Attach the brake control unit and adjust to the desired angle.
   • Tighten screws securely.

2. Under Dash Pocket Mount:

   • Secure the small metal bracket with screws to a flat surface.
   • Attach the T-slot mount to the metal bracket and insert the brake control.

Wiring the Brake Control:

• Option 1: Use the included pigtail wiring harness for a generic installation.
• Option 2: Use an OEM-specific wiring harness compatible with the vehicle's tow package.
• Wire Functions:
  • Black: Positive power (+12V).
  • White: Vehicle ground.
  • Red: Cold side of brake pedal switch.
  • Blue: Trailer brakes output.

Setting Up the Control:

1. Connect the trailer to the vehicle.
2. Use the Menu/Options button to access the setup screen.
3. Select the brake type:
   • Electric: For electric brakes.
   • Hydraulic: For electric over hydraulic braking systems.
4. Adjust the power output to ensure effective braking without wheel lock-up.

Boost Feature:

• Provides enhanced braking sensitivity.
• Available in three levels:
  • B1: Light braking boost.
  • B2: Moderate braking boost.
  • B3: Aggressive braking boost.
• Recommended for heavier trailers or varying load conditions.

Reverse Mode:

• Cancel Boost and Hold features for 3 minutes by pressing and holding the Boost button for 5 seconds while holding the brake pedal.

Troubleshooting Guide:

Maintenance:

• Inspect connections and wiring regularly for damage or wear.
• Adjust trailer brakes after the first 200 miles of use and every 3,000 miles thereafter.
• Clean the brake control unit periodically to maintain optimal performance.

Warranty Information:

• Limited Lifetime Warranty:
  • Covers defects in materials and workmanship under normal use.
  • Excludes damage caused by misuse, improper installation, or external factors.
• Attention: 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.