Installation Instructions for Dodge Sprinter, Freightliner Sprinter, and Mercedes Sprinter
(Van and Cab & Chassis Models)

Part Numbers:

• 75549
• 87441
• 44576
• 75239 UH

Tools Required:

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

Wiring Access Location:

• SUV1, SUV2

Step-by-Step Instructions:

For Sprinter Van Models:

1. Remove Tie-Down Hook:

   • Detach the tie-down hook from the passenger side frame rail.
   • Return the tie-down hook and fasteners to the vehicle owner.

2. Position the Hitch:

   • Raise the hitch into position.
   • Install the fasteners as shown:
     • Insert a hex bolt and lock washer through the round hole in the hitch bracket.
     • Insert hex bolts and toothed washers through the oblong slots in the hitch bracket, on both sides.

For Sprinter Cab & Chassis Models:

1. Remove Wheel Chock Bracket (if present):

   • Remove the wheel chock bracket from the driver side frame rail and retain it for reinstallation.
   • Discard the bolts.

2. Position the Hitch:

   • Raise the hitch and the wheel chock bracket into position.
   • Install the fasteners as shown:
     • Insert a hex bolt and lock washer through the round hole in the hitch bracket.
     • Insert hex bolts and toothed washers through the oblong slots in the hitch bracket, on both sides.

3. Tighten Fasteners:

   • Use a torque wrench to tighten all M12 x 1.75 CL8.8 fasteners to 68 lb-ft (92 N·m).

Hardware List:

• (8) Hex Bolts M12 x 1.75 x 120mm CL8.8
• (8) 1/4” x 1” x 2” Spacer Blocks
• (6) 1/2” Toothed Washers
• (8) Hex Nuts M12 x 1.75
• (2) 1/2” Lock Washers

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 7,500 lbs (3,405 kg), Max Tongue Weight 750 lbs (341 kg).
  • Weight Carrying (Ball Mount): Max Trailer Weight 6,000 lbs (2,724 kg), Max Tongue Weight 600 lbs (272 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 is not compatible with vehicles that have a 30-3/8” wide frame measured outside to outside.

Installation Instructions for Vehicles (Generic)
(Van and Cab & Chassis Models)

Part Numbers:

• 75549
• 87441
• 44576
• 75239 UH

Tools Required:

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

Wiring Access Location:

• SUV1, SUV2

Step-by-Step Instructions:

For Van Models:

1. Remove Tie-Down Hook:

   • Detach the tie-down hook from the passenger side frame rail.
   • Return the tie-down hook and fasteners to the vehicle owner.

2. Position the Hitch:

   • Raise the hitch into position.
   • Install the fasteners as shown:
     • Insert a hex bolt and lock washer through the round hole in the hitch bracket.
     • Insert hex bolts and toothed washers through the oblong slots in the hitch bracket, on both sides.

For Cab & Chassis Models:

1. Remove Wheel Chock Bracket (if present):

   • Remove the wheel chock bracket from the driver side frame rail and retain it for reinstallation.
   • Discard the bolts.

2. Position the Hitch:

   • Raise the hitch and the wheel chock bracket into position.
   • Install the fasteners as shown:
     • Insert a hex bolt and lock washer through the round hole in the hitch bracket.
     • Insert hex bolts and toothed washers through the oblong slots in the hitch bracket, on both sides.

3. Tighten Fasteners:

   • Use a torque wrench to tighten all M12 x 1.75 CL8.8 fasteners to 68 lb-ft (92 N·m).

Hardware List:

• (8) Hex Bolts M12 x 1.75 x 120mm CL8.8
• (8) 1/4” x 1” x 2” Spacer Blocks
• (6) 1/2” Toothed Washers
• (8) Hex Nuts M12 x 1.75
• (2) 1/2” Lock Washers

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 7,500 lbs (3,405 kg), Max Tongue Weight 750 lbs (341 kg).
  • Weight Carrying (Ball Mount): Max Trailer Weight 6,000 lbs (2,724 kg), Max Tongue Weight 600 lbs (272 kg).
• Complies with safety specifications and requirements for connecting devices and towing systems.

Attention:

This hitch is not compatible with vehicles that have a 30-3/8” wide frame measured outside to outside.

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 Dodge Sprinter, Mercedes Sprinter and Freightliner Sprinter

Part Numbers:

• 118650

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 and Torx 30 Drivers

Step-by-Step Instructions:

1. Prepare the Rear Area:

   • Open the rear doors and locate the plastic covers at the rear of the taillights on both sides.
   • Using a trim panel remover, carefully remove the three plastic covers on each side. The first cover exposes the taillight harness; the two upper covers assist with wire routing.

2. Locate the Taillight Wiring Harness:

   • On both the driver’s and passenger’s sides, locate the vehicle's taillight wiring harness.
   • Disconnect the connectors carefully to avoid breaking the locking tabs. Ensure all connector surfaces are clean and free of dirt.

3. Mount the Black Box:

   • Find a flat surface near the taillight area inside the vehicle.
   • Mount the T-One® T-Connector’s black box module to prevent damage or rattling.

4. Driver-Side T-Connector Installation:

   • Insert the T-One® T-Connector end with the yellow wire between the vehicle wiring connectors.
   • Ensure the connectors are fully inserted with locking tabs secured.

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 the existing wiring and route the wire to the passenger side. Secure it using the provided cable ties, concealing the wire behind the plastic covers where possible.

6. Passenger-Side T-Connector Installation:

   • Route the wires down through the holes exposed earlier and repeat Step 4 for the passenger side using the green wire.

7. Ground the White Wire:

   • Locate a suitable grounding point near the connector on the driver’s side.
   • Clean the grounding area and drill a 3/32” hole. Secure the white wire using the provided eyelet and screw.

   Caution:

   • Verify what is behind any surface before drilling to avoid vehicle damage or personal injury.

8. Connect the Power Wire:

   • From inside the vehicle, connect the black 12-gauge wire to the black wire from the T-One® T-Connector black box using the supplied yellow butt connector.
   • Route the wire through the channel to the roof area and then forward toward the driver’s seat, concealing the wire behind plastic covers where possible. Secure with cable ties.

9. Route the Wire to the Battery:

   • Continue routing the wire behind the trim panel next to the driver’s seat and down to the floor of the vehicle.
   • Access the vehicle battery beneath the driver’s side floor area by removing the trim threshold, floor covering, and metal battery cover.

10. Battery Connection:

    • Disconnect the negative (-) battery cable.
    • Cut the yellow fuse holder wire and attach the ring terminal. Secure it to the positive (+) battery cable.
    • Connect the other end of the fuse holder to the black 12-gauge wire using the supplied yellow butt connector.
    • Reconnect the negative (-) battery cable and install the 15-amp fuse into the fuse holder.

11. Secure Wiring:

    • Use the provided cable ties to secure the remainder of the T-One® T-Connector harness, avoiding areas that could pinch, cut, or melt the wire.

12. Reassemble the Vehicle:

    • Replace the plastic covers, battery cover, floor coverings, and all other components removed during installation.

13. Test the Installation:

    • Verify functionality using a test light or trailer. Reset the vehicle’s electrical system by temporarily removing the key from the ignition.

    Specifications:

    • Max. stop/turn light: 1 per side (2.1 amps)
    • Max. tail lights: (5.6 amps)

Safety Notes:

• Overloading circuits can cause fires. Do not exceed the lower of the towing manufacturer’s rating or the unit specifications.
• Always follow safety precautions and wear safety glasses during installation.

Manufacturer Notes:

• Store the 4-flat connector in the rear cargo area when not in use.
• Refer to the vehicle owner’s manual for additional details.

Installation Instructions for T-Connector Adapter for Dodge Sprinter, Mercedes Sprinter and Freightliner Sprinter

Part Numbers:

• 118650

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 and Torx 30 Drivers

Step-by-Step Instructions:

1. Prepare the Rear Area:

   • Open the rear doors and locate the plastic covers at the rear of the taillights on both sides.
   • Using a trim panel remover, carefully remove the three plastic covers on each side. The first cover exposes the taillight harness; the two upper covers assist with wire routing.

2. Locate the Taillight Wiring Harness:

   • On both the driver’s and passenger’s sides, locate the vehicle's taillight wiring harness.
   • Disconnect the connectors carefully to avoid breaking the locking tabs. Ensure all connector surfaces are clean and free of dirt.

3. Mount the Black Box:

   • Find a flat surface near the taillight area inside the vehicle.
   • Mount the T-One® T-Connector’s black box module to prevent damage or rattling.

4. Driver-Side T-Connector Installation:

   • Insert the T-One® T-Connector end with the yellow wire between the vehicle wiring connectors.
   • Ensure the connectors are fully inserted with locking tabs secured.

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 the existing wiring and route the wire to the passenger side. Secure it using the provided cable ties, concealing the wire behind the plastic covers where possible.

6. Passenger-Side T-Connector Installation:

   • Route the wires down through the holes exposed earlier and repeat Step 4 for the passenger side using the green wire.

7. Ground the White Wire:

   • Locate a suitable grounding point near the connector on the driver’s side.
   • Clean the grounding area and drill a 3/32” hole. Secure the white wire using the provided eyelet and screw.

   Caution:

   • Verify what is behind any surface before drilling to avoid vehicle damage or personal 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 supplied yellow butt connector.
   • Route the wire through the channel to the roof area and then forward toward the driver’s seat, concealing the wire behind plastic covers where possible. Secure with cable ties.

9. Route the Wire to the Battery:

   • Continue routing the wire behind the trim panel next to the driver’s seat and down to the floor of the vehicle.
   • Access the vehicle battery beneath the driver’s side floor area by removing the trim threshold, floor covering, and metal battery cover.

10. Battery Connection:

    • Disconnect the negative (-) battery cable.
    • Cut the yellow fuse holder wire and attach the ring terminal. Secure it to the positive (+) battery cable.
    • Connect the other end of the fuse holder to the black 12-gauge wire using the supplied yellow butt connector.
    • Reconnect the negative (-) battery cable and install the 15-amp fuse into the fuse holder.

11. Secure Wiring:

    • Use the provided cable ties to secure the remainder of the T-One® T-Connector harness, avoiding areas that could pinch, cut, or melt the wire.

12. Reassemble the Vehicle:

    • Replace the plastic covers, battery cover, floor coverings, and all other components removed during installation.

13. Test the Installation:

    • Verify functionality using a test light or trailer. Reset the vehicle’s electrical system by temporarily removing the key from the ignition.

Specifications:

• Max. stop/turn light: 1 per side (2.1 amps)
• Max. tail lights: (5.6 amps)

Safety Notes:

• Overloading circuits can cause fires. Do not exceed the lower of the towing manufacturer’s rating or the unit specifications.
• Always follow safety precautions and wear safety glasses 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:

• Store the 4-flat connector in the rear cargo area when not in use.
• Refer to the vehicle owner’s manual for additional details.

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.