Installation Instructions for Trailer Hitch #76194, #84194, and #CQT76194

Part Numbers:

• 76194
• 84194
• CQT76194

Applications:

• Years: 2016–Current (Volvo XC90), 2018–Current (Volvo XC60)

For the most up-to-date application years and trim levels, consult the manufacturer’s website.

Tools Required:

• Ratchet
• Torque Wrench
• Safety Glasses
• Sockets: 15 mm
• 6" Socket Extension
• T20 Star Driver
• Tin Snips
• Marker
• Tape Measure
• Exhaust Removal Pliers
• Utility Knife

Step-by-Step Instructions:

1. Fascia and Bumper Beam Removal:

• Use a T20 star driver to remove (4) screws from the bottom fascia.
• Remove screws from the wheel wells:
  • XC90: Remove (5) screws on each side.
  • XC60: Remove (7) screws on each side.
• Open the trunk (for XC60, remove bump stops), gently remove the fascia, and unplug any wiring:
  • XC90: Disconnect 2 wirings.
  • XC60: Disconnect 1 wiring.
• Set the fascia aside carefully.
• Use a 15 mm socket to remove (3) flange nuts from the bumper beam on each side, then remove the bumper beam and fasteners.
  • Some models may have (4) flange nuts.

2. Heat Shield Trimming:

• Trim the heat shield as specified in the instructions (refer to Figure 3).

3. Bend Fascia Mounting Tabs:

• XC90 Models: Skip this step.
• XC60 Models: Gently bend the fascia mounting tabs as shown in Figure 4 to allow clearance for the hitch.

4. Hitch Installation:

• Raise the hitch into position, aligning the bracket holes with the studs on the end panel.
• Raise the bumper beam to sandwich the hitch and reuse the flange nuts (refer to Figure 1).
• If the fourth hole in the bumper is open, use the additional hardware (refer to Figure 5).
• XC60 Models: Before reattaching the fascia and heat shield, gently bend the fascia mounting tabs as needed.

5. Tighten Fasteners:

• Torque all M10 fasteners to 53 lb-ft (72 N·m).

6. Fascia Trimming and Reinstallation:

• Mark the centerline on the fascia and trim the area as shown in Figure 6.
• Reinstall all fasteners, wiring, exhaust hanger, and fascia removed in Steps 1 and 2.
• After reinstalling the fascia, gently bend the fascia mounting tabs as needed to align them properly.

Hardware List:

• 2 × Conical Washers (7/16")
• 2 × M10 × 1.5 × 45 mm Bolts (CL10.9)

Safety Notes:

• Always wear safety glasses during installation.
• Proper torque is essential to secure the hitch to the vehicle.
• Check the hitch periodically to ensure all fasteners and the hitch ball are secure.
• Plug any exposed holes in the trunk pan or body panels if the hitch is removed to prevent water and exhaust fumes from entering the vehicle.
• Replace any damaged hitch or hitch ball before use.
• Do not cut access or attachment holes with a torch.

Specifications:

• Max Gross Trailer Weight (Weight Carrying): 6,000 lbs (2,724 kg)
• Max Tongue Weight (Weight Carrying): 900 lbs (409 kg)
• Weight Distribution: Not applicable
• Installation Time: Approximately 65 minutes

This product complies with V.E.S.C. Regulation V-5 and SAE J684 safety specifications for towing systems.

Technical Support:

For assistance, visit www.trailerjacks.com or call 877-869-6690.

Attention: This is a summary of the installation procedure. For complete instructions, including diagrams, please download the full installation PDF.

Installation Instructions for T-One® T-Connector for Volvo XC60

Part Numbers:

• 118773

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

Step-by-Step Instructions:

1. Remove Interior Panels:

• Open the tailgate and remove the cargo door on the floor.
• Carefully remove the floor trim panels and access panels on each side of the vehicle.
• Set aside all items removed, being careful not to damage parts.

2. Locate the Taillight Wiring Harness:

• On both the driver and passenger sides, locate the vehicle’s taillight wiring harness inside the access panel area.
• The taillight wiring harness has a connection point matching the ends of the T-One® T-Connector.
• Disconnect the harness carefully, ensuring not to break the locking tabs. Clean all connector surfaces to remove dirt.

3. Connect the Driver-Side T-Connector:

• Insert the T-One® Connector end with the yellow wire between the vehicle wiring connectors.
• Lock the connectors into place, ensuring they are fully inserted and secure.

4. Route the Passenger-Side T-Connector:

• Route the connector containing the green wire down the threshold to the passenger side of the vehicle.
• Insert the T-One® Connector end with the green wire between the passenger-side taillight wiring connectors.

5. Ground the White Wire:

• Locate a suitable grounding point near the connector, such as the vehicle’s frame or crossmember.
• Clean the area of dirt and rustproofing.
• 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. Route the Power Wire:

• Locate the black 12-gauge power wire from the T-One® Connector box.
• Attach the provided black wire and route it along the vehicle’s exterior frame or follow existing wiring into the engine compartment up to the battery.

Warning: Avoid routing near hot pipes, heat shields, or areas that may pinch or damage the wire.

7. Connect to the Vehicle Battery:

• Disconnect the Negative (-) battery cable.
• Remove the fuse from the yellow fuse holder.
• Attach the ring terminal to the Positive (+) battery cable and secure it.
• Connect the other end of the fuse holder to the black wire using the provided yellow butt connector.

8. Reconnect the Battery and Test:

• Reconnect the Negative (-) battery cable.
• Insert the 15-amp fuse into the fuse holder.
• Test the installation using a test light or trailer. Reset the vehicle’s electrical system by temporarily removing the key from the ignition.

9. Mount the Black Box Module:

• Locate a flat surface in an out-of-the-way place and mount the T-One® Connector’s black box module to prevent damage or rattling.

10. Secure the Wiring Harness:

- Use the provided cable ties to secure the harness, avoiding areas that may pinch, cut, or melt the wire.

11. Reassemble the Vehicle:

- Replace both access panels, spare tire cover, cargo floor hatch, and cargo nets removed during installation.

12. Store the 4-Flat Connector:

- Store the 4-flat connector in the rear cargo area when not in use.

Safety Notes:

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

Warranty Information:

• Warranty Duration: This product is covered by a limited lifetime warranty.
• Coverage: The warranty covers defects in materials and workmanship under normal use.
• Warranty Instructions: For complete warranty instructions, please download the full installation PDF.

Manufacturer Notes:

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

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 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.