Installation Instructions for Chrysler Town & Country, Dodge Grand Caravan, VW Routan, and Ram C/V Tradesman

Part Numbers:

• 75579
• 87451
• 44586

Tools Required:

• Wrenches: 13mm, 15mm, 18mm
• Drill Bits: None

Wiring Access Location:

• SUV1, SUV2

Step-by-Step Instructions:

1. Lower Exhaust:

   • Remove the bolt attaching the rearmost hanger bracket to the passenger-side frame rail.
   • Retain the bolt for reinstallation.

2. Install Plastic Loom (if applicable):

   • Snap the plastic loom in place over the air conditioning line near the bolt (if present) to protect it. See Figure 2.

3. Remove Existing Bolts:

   • On the driver's side, remove three (3) bolts from the frame rail.
   • On the passenger's side, remove two (2) bolts.
   • Retain all bolts for hitch installation.

4. Remove Plastic Rivet (Driver's Side):

   • Remove the plastic rivet securing the plastic mud flap to the driver's side frame rail.
   • After hitch installation, trim the plastic corner of the mud flap if necessary.
   • Do not reinstall the plastic rivet.

5. Raise the Hitch:

   • Position the hitch and secure it with the bolts removed in Step 3.
   • Hand-tighten the fasteners.

6. Align Hitch:

   • Push the hitch toward the driver's side so the passenger-side bracket contacts the trunk pan.

7. Tighten Fasteners:

   • Torque all M10 CL10.9 fasteners to 53 lb-ft (72 N·m).
   • Torque all M12 CL10.9 fasteners to 92 lb-ft (125 N·m).

8. Reinstall Exhaust:

   • Raise the exhaust back into position and reinstall the bolt removed in Step 1.

   Note: Rotating the exhaust hanger bracket before tightening will provide additional clearance between the hitch bracket and exhaust.

Hardware List:

• (5) Existing M10 Bolts (from vehicle frame)
• (2) Existing M12 Bolts (from vehicle frame)

Safety Notes:

• Check the hitch frequently to ensure all fasteners and the ball are properly tightened.
• If the hitch is removed, plug all holes in the trunk pan or body panels to prevent water and exhaust fumes from entering.
• Replace any damaged hitch or ball immediately.
• Follow all 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 Distributing: Max Trailer Weight 5,000 lbs (2,270 kg), Max Tongue Weight 500 lbs (227 kg).
  • Weight Carrying (Ball Mount): Max Trailer Weight 4,000 lbs (1,816 kg), Max Tongue Weight 400 lbs (182 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.

Installation Instructions for Vehicles (Generic)

Part Numbers:

• 75579
• 87451
• 44586

Tools Required:

• Wrenches: 13mm, 15mm, 18mm
• Drill Bits: None

Wiring Access Location:

• SUV1, SUV2

Step-by-Step Instructions:

1. Lower Exhaust:

   • Remove the bolt attaching the rearmost hanger bracket to the passenger-side frame rail.
   • Retain the bolt for reinstallation.

2. Install Plastic Loom (if applicable):

   • Snap the plastic loom in place over the air conditioning line near the bolt (if present) to protect it. See Figure 2.

3. Remove Existing Bolts:

   • On the driver's side, remove three (3) bolts from the frame rail.
   • On the passenger's side, remove two (2) bolts.
   • Retain all bolts for hitch installation.

4. Remove Plastic Rivet (Driver's Side):

   • Remove the plastic rivet securing the plastic mud flap to the driver's side frame rail.
   • After hitch installation, trim the plastic corner of the mud flap if necessary.
   • Do not reinstall the plastic rivet.

5. Raise the Hitch:

   • Position the hitch and secure it with the bolts removed in Step 3.
   • Hand-tighten the fasteners.

6. Align Hitch:

   • Push the hitch toward the driver's side so the passenger-side bracket contacts the trunk pan.

7. Tighten Fasteners:

   • Torque all M10 CL10.9 fasteners to 53 lb-ft (72 N·m).
   • Torque all M12 CL10.9 fasteners to 92 lb-ft (125 N·m).

8. Reinstall Exhaust:

   • Raise the exhaust back into position and reinstall the bolt removed in Step 1.

   Note: Rotating the exhaust hanger bracket before tightening will provide additional clearance between the hitch bracket and exhaust.

Hardware List:

• (5) Existing M10 Bolts (from vehicle frame)
• (2) Existing M12 Bolts (from vehicle frame)

Safety Notes:

• Check the hitch frequently to ensure all fasteners and the ball are properly tightened.
• If the hitch is removed, plug all holes in the trunk pan or body panels to prevent water and exhaust fumes from entering.
• Replace any damaged hitch or ball immediately.
• Follow all 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 4,000 lbs (1,816 kg), Max Tongue Weight 400 lbs (182 kg).
  • Weight Distributing: Max Trailer Weight 5,000 lbs (2,270 kg), Max Tongue Weight 500 lbs (227 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.

Installation Instructions for T-Connector Adapter for Volkswagen Routan

Part Numbers:

• 118490

Tools Required:

• Trim Panel Remover
• Torx 30 Driver
• Drill (3/32” Drill Bit)
• 1/4” Socket
• Utility Knife
• Wire Cutters
• Phillips Head Screwdriver
• Test Probe

Step-by-Step Instructions:

1. Remove the Taillight Assemblies:

   • Open the tailgate and remove the vehicle’s taillight assemblies by removing the two T30 Torx head bolts on each side.
   • Carefully pry the taillight housings rearward, ensuring not to break the alignment tabs.

2. Disconnect the Driver-Side Wiring Harness:

   • Disconnect the vehicle wiring harness from the driver-side taillight socket.
   • Plug the T-Connector end with the yellow wire between the mating plugs on the driver-side taillight socket and vehicle wiring harness.
   • Ensure the connectors are clean, fully inserted, and locked in place.

3. Route the Passenger-Side T-Connector:

   • Route the harness containing the green wire down the opening behind the driver-side taillight.
   • Then, route the harness across and underneath the vehicle behind the bumper fascia and up through the opening behind the passenger-side taillight.

   Warning:

   • Avoid routing near hot pipes, heat shields, the fuel tank, or areas where the wire may be pinched or damaged.

4. Install the Passenger-Side T-Connector:

   • Repeat step 2 for the passenger-side T-Connector containing the green wire.

5. Ground the White Wire:

   • Locate a suitable grounding point near the connector, such as the vehicle’s frame or cross member.
   • Clean the area, drill a 3/32” hole, and secure the white wire using the provided eyelet and screw.

   Caution:

   • Verify what is behind the surface before drilling to avoid damage or injury. Do not drill into exposed surfaces.

6. Access the Jack Storage Area:

   • Open the jack storage door, remove the jack, tools, and carpeting to access the vehicle wiring.

7. Modify the Vehicle Wiring Grommet:

   • On the driver’s side, pull the taillight wire harness and unseat the grommet.
   • Remove the grommet from the vehicle harness by untaping the tabs and slitting the grommet.

8. Route the 4-Flat Connector:

   • Route the vehicle connector and the 4-flat end through the grommet hole into the jack storage area.
   • Store the 4-flat connector in the jack storage compartment when not in use.

   Note:

   • Route the 4-flat harness through the rear tailgate/door seal when in use.
   • Be careful not to pinch the harness in the door latch.

9. Secure the Grommet:

   • Place the grommet onto the T-Connector wiring between the T-Connector and the vehicle’s mating end.
   • Retape the tabs to secure the grommet and reseat it into the vehicle hole.

10. Secure and Reassemble:

    • Secure all loose wires with cable ties.
    • Reinstall the taillight assemblies and any other items removed during installation, ensuring no wires are pinched or cut.

11. Test the Installation:

    • Test the T-Connector installation with a test light or trailer to ensure proper functionality.

    Specifications:

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

Safety Notes:

• Overloading circuits can cause fires. Do not exceed the towing manufacturer’s rating or the unit specifications.
• Follow all warnings and installation instructions carefully.

Manufacturer Notes:

• Refer to the vehicle owner’s manual for additional guidance.

Installation Instructions for T-Connector Adapter for Vehicle

Part Numbers:

• 118490

Tools Required:

• Trim Panel Remover
• Torx 30 Driver
• Drill (3/32” Drill Bit)
• 1/4” Socket
• Utility Knife
• Wire Cutters
• Phillips Head Screwdriver
• Test Probe

Step-by-Step Instructions:

1. Remove the Taillight Assemblies:

   • Open the tailgate and remove the vehicle’s taillight assemblies by removing the two T30 Torx head bolts on each side.
   • Carefully pry the taillight housings rearward, ensuring not to break the alignment tabs.

2. Disconnect the Driver-Side Wiring Harness:

   • Disconnect the vehicle wiring harness from the driver-side taillight socket.
   • Plug the T-Connector end with the yellow wire between the mating plugs on the driver-side taillight socket and vehicle wiring harness.
   • Ensure the connectors are clean, fully inserted, and locked in place.

3. Route the Passenger-Side T-Connector:

   • Route the harness containing the green wire down the opening behind the driver-side taillight.
   • Then, route the harness across and underneath the vehicle behind the bumper fascia and up through the opening behind the passenger-side taillight.

   Warning:

   • Avoid routing near hot pipes, heat shields, the fuel tank, or areas where the wire may be pinched or damaged.

4. Install the Passenger-Side T-Connector:

   • Repeat step 2 for the passenger-side T-Connector containing the green wire.

5. Ground the White Wire:

   • Locate a suitable grounding point near the connector, such as the vehicle’s frame or cross member.
   • Clean the area, drill a 3/32” hole, and secure the white wire using the provided eyelet and screw.

   Caution:

   • Verify what is behind the surface before drilling to avoid damage or injury. Do not drill into exposed surfaces.

6. Access the Jack Storage Area:

   • Open the jack storage door, remove the jack, tools, and carpeting to access the vehicle wiring.

7. Modify the Vehicle Wiring Grommet:

   • On the driver’s side, pull the taillight wire harness and unseat the grommet.
   • Remove the grommet from the vehicle harness by untaping the tabs and slitting the grommet.

8. Route the 4-Flat Connector:

   • Route the vehicle connector and the 4-flat end through the grommet hole into the jack storage area.
   • Store the 4-flat connector in the jack storage compartment when not in use.

   Note:

   • Route the 4-flat harness through the rear tailgate/door seal when in use.
   • Be careful not to pinch the harness in the door latch.

9. Secure the Grommet:

   • Place the grommet onto the T-Connector wiring between the T-Connector and the vehicle’s mating end.
   • Retape the tabs to secure the grommet and reseat it into the vehicle hole.

10. Secure and Reassemble:

    • Secure all loose wires with cable ties.
    • Reinstall the taillight assemblies and any other items removed during installation, ensuring no wires are pinched or cut.

11. Test the Installation:

    • Test the T-Connector installation with a test light or trailer to ensure proper functionality.

    Specifications:

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

Safety Notes:

• Overloading circuits can cause fires. Do not exceed the towing manufacturer’s rating or the unit specifications.
• Follow all warnings and installation instructions carefully.

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:

• This product is covered by a [warranty period]. 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.

Manufacturer Notes:

• Refer to the vehicle owner’s manual for additional guidance.

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.