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 XC90

Part Numbers:

• 118683

Tools Required:

• 10mm Socket & Ratchet or 10mm Wrench
• Trim Panel Remover
• Drill (3/32” Drill Bit)
• Phillips Head Screwdriver

Step-by-Step Instructions:

1. Prepare the Vehicle:

   • 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 removed items, ensuring they are not damaged.

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.
   • Disconnect the connectors carefully, ensuring the locking tabs are not damaged. Clean all connector surfaces.

3. Connect the Driver-Side T-Connector:

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

4. Route the Passenger-Side T-Connector:

   • Route the T-Connector end with the green wire through the trim panel access hole, across the threshold, and into the passenger trim panel access hole.
   • Repeat Step 3 for 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 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 any surface before drilling to avoid damage or injury.

6. Connect the Power Wire:

   • On the driver’s side, locate the power cable stud.
   • Remove the nut using a wrench or socket, place the ring terminal with the orange wire on the stud, and retighten the nut.
   • Insert the 15-amp fuse into the fuse holder.

   Warning: All connections must be complete for the T-Connector to function properly. Test and verify the installation with a test light or trailer.

7. Mount the Black Box Module:

   • Clean a flat area in the driver’s side storage area with a mixture of rubbing alcohol and water.
   • Mount the T-Connector black box using the provided double-sided tape.

8. Secure the Wiring Harness:

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

9. Reassemble the Vehicle:

   • Replace the access panels, floor trim panels, and cargo door removed during installation.

10. Store the 4-Flat Connector:

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

Specifications:

• Max. stop/turn light: 2 per side (4.2 amps)
• Max. tail lights: 7.5 amps

Safety Notes:

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

Manufacturer Notes:

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

Installation Instructions for T-One® T-Connector for Volvo XC90

Part Numbers:

• 118683

Tools Required:

• 10mm Socket & Ratchet or 10mm Wrench
• Trim Panel Remover
• Drill (3/32” Drill Bit)
• Phillips Head Screwdriver

Step-by-Step Instructions:

1. Prepare the Vehicle:

   • 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 removed items, ensuring they are not damaged.

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.
   • Disconnect the connectors carefully, ensuring the locking tabs are not damaged. Clean all connector surfaces.

3. Connect the Driver-Side T-Connector:

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

4. Route the Passenger-Side T-Connector:

   • Route the T-Connector end with the green wire through the trim panel access hole, across the threshold, and into the passenger trim panel access hole.
   • Repeat Step 3 for 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 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 any surface before drilling to avoid damage or injury.

6. Connect the Power Wire:

   • On the driver’s side, locate the power cable stud.
   • Remove the nut using a wrench or socket, place the ring terminal with the orange wire on the stud, and retighten the nut.
   • Insert the 15-amp fuse into the fuse holder.

   Warning: All connections must be complete for the T-Connector to function properly. Test and verify the installation with a test light or trailer.

7. Mount the Black Box Module:

   • Clean a flat area in the driver’s side storage area with a mixture of rubbing alcohol and water.
   • Mount the T-Connector black box using the provided double-sided tape.

8. Secure the Wiring Harness:

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

9. Reassemble the Vehicle:

   • Replace the access panels, floor trim panels, and cargo door removed during installation.

10. Store the 4-Flat Connector:

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

Specifications:

• Max. stop/turn light: 2 per side (4.2 amps)
• Max. tail lights: 7.5 amps

Safety Notes:

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

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.

Manufacturer Notes:

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

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.

Warranty:

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.