Installation Instructions for Dodge Journey

Part Numbers:

• 75648
• 87487
• 44601

Tools Required:

• Wrenches: 3/4”
• Lubricant or soapy water
• Tape

Wiring Access Location:

• SUV1, SUV2

Step-by-Step Instructions:

1. Lower the Exhaust:

   • Remove all rubber isolators behind the rear axle (two or three depending on the vehicle).
   • Be careful not to let the mufflers fall under their own weight.
   • Tip: Spray lubricant or soapy water on the metal hanger rod and rubber isolator to ease removal.

2. Install Carriage Bolts:

   • Feed spacers and carriage bolts into the impact bar using the pull wires provided (both sides).
   • Leave the pull wire attached for alignment.

3. Tape Spacers to the Hitch:

   • Tape the spacers in place on the hitch before raising it into position.
   • Orient spacers as shown in the diagrams.

4. Raise the Hitch:

   • Single exhaust: Raise the hitch on the passenger side over the exhaust pipe and slowly rotate it into position.
   • Dual exhaust: Slide the hitch above the tailpipes.
   • Secure the hitch with conical washers and nuts.

5. Insert Handle Nuts:

   • Bend and insert handle nuts through access holes in the frame.
   • Install two (2) 1/2"-13 bolts and conical washers as shown.
   • Hold handle nuts in place to prevent rotation and bend the ends out of the way.

6. Tighten Fasteners:

   • Tighten 1/2"-13 carriage bolts to 75 lb-ft (102 N·m).
   • Tighten handle nuts to 50 lb-ft (68 N·m).

7. Reattach the Exhaust:

   • Raise the exhaust back into position and reconnect the rubber isolators.
   • Note: If additional exhaust clearance is needed, bend the exhaust hanger bracket (welded to the vehicle frame) downward.

Hardware List:

• (2) Carriage Bolts 1/2"-13 x 2.25” GR5
• (2) Hex Bolts 1/2"-13 x 1.50” GR5
• (4) Conical Washers
• (4) Bevel Spacers
• (2) Spacers
• (2) Handle Nuts
• (2) Pull Wires
• (2) Hex Nuts 1/2"-13

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 body panels to prevent water and exhaust fumes from entering.
• Replace any damaged hitch or ball immediately.
• 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 Distributing: Max Trailer Weight 4,000 lbs (1,816 kg), Max Tongue Weight 400 lbs (182 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 T-Connector Adapter for Dodge Journey

Part Numbers:

• 118495

Tools Required:

• Trim Panel Remover
• 10mm Socket & Ratchet or 10mm Wrench
• Drill (3/32” Drill Bit)
• Test Probe

Step-by-Step Instructions:

1. Remove the Right-Side Taillight Assembly:

   • Open the tailgate.
   • Remove the vehicle’s right-side taillight assembly by removing the two clips holding the taillight in place.
   • Locate the connection points behind each taillight housing that match the T-Connector adapter ends.

2. Install the Driver-Side T-Connector:

   • Separate the vehicle’s wiring connectors on the driver’s side, ensuring not to break the locking tabs.
   • Insert the T-Connector end with the yellow wire between the vehicle connectors.
   • Ensure all connectors are clean, fully inserted, and the locking tabs are secure.

3. Route the Wiring:

   • Route the T-Connector harness containing the green wire and the 4-flat connector down through the opening behind the driver’s side taillight.
   • Route the 4-flat connector to the center of the vehicle.
   • Route the green wire underneath the vehicle to the passenger-side taillight opening.

4. Install the Passenger-Side T-Connector:

   • Repeat step 2 on the passenger side using the T-Connector with the green wire.

5. Ground the White Wire:

   • Locate a suitable grounding point near the connector, such as an existing ground stud.
   • If no ground stud is available, drill a 3/32” hole.
   • Clean the area of dirt and rustproofing and secure the white wire using the provided eyelet and screw.

   Caution:

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

6. Store the 4-Flat Connector:

   • When not in use, store the 4-flat connector in the spare tire compartment.
   • A mounting bracket for the 4-flat connector is sold separately.

7. Test the Installation:

   • Test and verify the installation using 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)
   • Max. tail lights: (7.5 amps)

Safety Notes:

• Overloading circuits can cause fires. Do not exceed the towing manufacturer’s rating or the specified maximum ratings.
• Follow all installation instructions carefully.

Manufacturer Notes:

• Refer to the vehicle owner’s manual for additional guidance.
• Always use safety glasses and follow safety precautions during installation.

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 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.