Installation Instructions for Dodge Ram 2500 and 3500 (2003–2016)

Part Numbers:

• 45509
• 45709
• CQT45509

Wiring Access Location:

• Not specified

Tools Required:

• Wrenches: 16mm, 18mm, 21mm
• Drill Bit: 9/16"
• Torque Wrench
• Safety Glasses
• Ratchet with a 6" Socket Extension
• Wooden Block (2" thick)
• Die Grinder (if necessary)

Installation Time:

• Approximately 95 minutes for professional installers

Step-by-Step Instructions:

1. Lower Spare Tire:

   • Lower the spare tire for easier access.
   • For vehicles with an 18" spare tire, remove the spare tire locator bracket. A 20" spare tire must be relocated from under the bed.

2. Remove Rear Bed Bolts:

   • Remove the six rearmost bed attachment bolts through the large holes in the frame or suspension mounts.
   • Leave the two forward-most bed bolts tightened.

3. Raise Bed:

   • Lift the rear of the bed and insert a 2" wooden block between the frame and the #3 bed attachment point.

4. Remove License Plate and Bumper:

   • Remove the license plate to access bolts.
   • Detach the bumper by removing 6 to 12 bolts depending on the model year:
     • 2003–2009 Models: Remove two M12 bolts and one M14 bolt per side from the inner bumper corner brace to the hitch attachment.
     • 2010 Models: Remove two M12 bolts per side from the frame rail bumper attachment to the bumper.
     • All years: Remove two M12 bolts in the license plate area.

5. Remove OEM Hitch Structure:

   • For 2003–2009 models, remove the last two M14 bolts from the frame rail.
   • For 2010 models, remove three M14 bolts from the frame rail.
   • Rotate and pull the OEM structure to clear boss and tab/slot engagements.

6. Install Hitch:

   • Lower the bed and reinstall the bed bolts.
   • Raise the hitch into position and use the forward-most M14 bolts to hold it in place temporarily.

7. Mark and Drill Holes:

   • Use the hitch as a template to mark and drill 9/16" holes in the bottom of the frame.

8. Fishwire Fasteners:

   • Insert 1/2" carriage bolts and blocks into position through the end of the frame using the supplied pull wires.
   • Attach 1/2" conical washers and nuts finger-tight.

9. Reinstall Bumper:

   • Reattach the bumper using bolts removed earlier. Loosen bolts on corner braces (2003–2009 models) to ease installation.
   • Adjust the gap between the bumper and tailgate for even spacing before tightening.

10. Reinstall Spare Tire:

    • Raise the spare tire back into position.

11. Final Tightening:

    • Torque all fasteners to the specified values:
      • M12 fasteners: 75 lb-ft (102 N*m)
      • M14 and 1/2" fasteners: 100 lb-ft (136 N*m)
      • Bed fasteners: 85 lb-ft (115 N*m)

Torque Specifications:

• M12 fasteners: 75 lb-ft (102 N*m)
• M14 fasteners: 100 lb-ft (136 N*m)
• 1/2" fasteners: 100 lb-ft (136 N*m)

Hardware List:

• (4) Hex Nuts, M14 x 2.00
• (6) Hex Nuts, M12 x 1.75
• (14) Conic

Installation Instructions for Gooseneck Mounting Kit

Part Numbers:

• 45509
• 45709
• CQT45509

Wiring Access Location:

• Not specified

Tools Required:

• Wrenches: 16mm, 18mm, 21mm
• Drill Bit: 9/16"
• Torque Wrench
• Safety Glasses
• Ratchet with a 6" Socket Extension
• Wooden Block (2" thick)
• Die Grinder (if necessary)

Installation Time:

• Approximately 95 minutes for professional installers

Step-by-Step Instructions:

1. Lower Spare Tire:

   • Lower the spare tire for easier access.
   • For vehicles with an 18" spare tire, remove the spare tire locator bracket. A 20" spare tire must be relocated from under the bed.

2. Remove Rear Bed Bolts:

   • Remove the six rearmost bed attachment bolts through the large holes in the frame or suspension mounts.
   • Leave the two forward-most bed bolts tightened.

3. Raise Bed:

   • Lift the rear of the bed and insert a 2" wooden block between the frame and the #3 bed attachment point.

4. Remove License Plate and Bumper:

   • Remove the license plate to access bolts.
   • Detach the bumper by removing 6 to 12 bolts depending on the model year:
     • 2003–2009 Models: Remove two M12 bolts and one M14 bolt per side from the inner bumper corner brace to the hitch attachment.
     • 2010 Models: Remove two M12 bolts per side from the frame rail bumper attachment to the bumper.
     • All years: Remove two M12 bolts in the license plate area.

5. Remove OEM Hitch Structure:

   • For 2003–2009 models, remove the last two M14 bolts from the frame rail.
   • For 2010 models, remove three M14 bolts from the frame rail.
   • Rotate and pull the OEM structure to clear boss and tab/slot engagements.

6. Install Hitch:

   • Lower the bed and reinstall the bed bolts.
   • Raise the hitch into position and use the forward-most M14 bolts to hold it in place temporarily.

7. Mark and Drill Holes:

   • Use the hitch as a template to mark and drill 9/16" holes in the bottom of the frame.

8. Fishwire Fasteners:

   • Insert 1/2" carriage bolts and blocks into position through the end of the frame using the supplied pull wires.
   • Attach 1/2" conical washers and nuts finger-tight.

9. Reinstall Bumper:

   • Reattach the bumper using bolts removed earlier. Loosen bolts on corner braces (2003–2009 models) to ease installation.
   • Adjust the gap between the bumper and tailgate for even spacing before tightening.

10. Reinstall Spare Tire:

    • Raise the spare tire back into position.

11. Final Tightening:

    • Torque all fasteners to the specified values:
      • M12 fasteners: 75 lb-ft (102 N*m)
      • M14 and 1/2" fasteners: 100 lb-ft (136 N*m)
      • Bed fasteners: 85 lb-ft (115 N*m)

Torque Specifications:

• M12 fasteners: 75 lb-ft (102 N*m)
• M14 fasteners: 100 lb-ft (136 N*m)
• 1/2" fasteners: 100 lb-ft (136 N*m)

Hardware List:

• (4) Hex Nuts, M14 x 2.00
• (6) Hex Nuts, M12 x 1.75
• (14) Conical Washers, 1/2"
• (8) Lock Washers, 1/2"
• (8) Hex Nuts, 1/2"-13 GR5
• (4) Spacer Blocks, 0.250" x 1" x 2"
• (4) Spacer Blocks, 0.250" x 1.5" x 3"
• (2) Flat Washers, 1/2"
• (2) 1/2" Carriage Bolts
• (2) Pull Wires (provided)

Safety Notes:

• Regularly check the hitch to ensure all fasteners and the ball are securely tightened.
• If the hitch is removed, plug all holes in the frame or body panels to prevent water or exhaust fumes from entering.
• Replace any damaged hitch or ball immediately.
• Always wear safety glasses and observe safety precautions when working beneath the vehicle.
• Do not cut access or attachment holes with a torch.

Specifications:

• Weight Carrying (Ball Mount):
  • Max Gross Trailer Weight: 12,000 lb (5,448 kg)
  • Max Tongue Weight: 1,200 lb (545 kg)
• Weight Distributing:
  • Max Gross Trailer Weight: 14,000 lb (6,356 kg)
  • Max Tongue Weight: 1,700 lb (771 kg)

Additional Notes:

• This product complies with V.E.S.C. Regulation V-5 and SAE J684 safety standards.
• Not recommended for use on 1/2-ton vehicles.
• Scan the QR code provided on the manual for step-by-step photo instructions.

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.

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.

Installation Instructions for Trailer Light Wiring Kit

Part Number:

• 20252

Tools Required:

• Hot Air Gun or Appropriate Heat Source
• Wire Crimpers
• Drill (3/32” Drill Bit)
• Phillips Head Screwdriver
• Circuit Tester

Step-by-Step Instructions:

Step 1: Locate the Taillight Wiring Harness

1. Access the vehicle's taillight wiring harness.
2. Using the provided instructions, identify the appropriate wires for connection:
   • Green Wire: Right Turn & Stop
   • Yellow Wire: Left Turn & Stop
   • Brown Wire: Taillights
   • White Wire: Ground

Step 2: Make the Electrical Connections

1. Match the color-coded wires from the wiring kit to the corresponding vehicle wires.

   • Use a circuit tester to verify each wire's function before connecting.
   • CAUTION: Test one wire at a time to prevent damage to electronic components.

2. Connect the wires using the provided insulated butt connectors:

   • Strip the ends of each wire and seat them properly in the connector.
   • Use a crimping tool designed for insulated splices to secure the connections.

3. Heat the connectors:

   • Apply heat directly to the center of each splice using a hot air gun.
   • Work from the center outward until the tubing recovers and adhesive flows.
   • Allow the connections to cool before inspecting for integrity.

Step 3: Ground the System

1. Locate a grounding point near the wiring harness, such as the vehicle frame or cross member.
   • Do not drill into the vehicle floor or bed.
2. Clean the area to remove dirt, rust, or undercoating.
3. Drill a 3/32" hole at the grounding point and secure the white wire using the provided eyelet and screw.

Step 4: Verify the Installation

1. Test all connections using a circuit tester or trailer:
   • Verify the functionality of taillights, turn signals, and brake lights.
   • Ensure all connections are complete and secure.
2. If issues are identified, double-check the wiring and connections for errors.

Step 5: Store the 4-Flat Connector

• Store the 4-flat connector in the rear cargo area when not in use to protect it from damage and environmental exposure.

Warnings and Notes:

• WARNING: Overloading a circuit can cause fires. Do not exceed the following limits:
  • Stop/Turn Lights: 7.5 amps (1 per side)
  • Tail Lights: 7.5 amps
• WARNING: Always verify what is behind any surface before drilling to avoid vehicle damage or injury.
• NOTE: Trailer lighting that requires more than 7.5 amps per circuit must use a Trailer Light Power Converter.
• NOTE: If your trailer requires a plug other than the 4-flat, consult your dealer for optional 6-way or 7-way adapters.

Maintenance:

• Inspect the wiring harness periodically for damage, corrosion, or loose connections.
• Reapply heat to connectors if the adhesive seal weakens.

Specifications:

• Maximum Load:
  • Stop/Turn Lights: 7.5 amps (1 per side)
  • Tail Lights: 7.5 amps
• Recommended Grounding Hole Size: 3/32 inches

Installation Instructions for Trailer Light Wiring Kit

Part Number:

• 20252

Tools Required:

• Hot Air Gun or Appropriate Heat Source
• Wire Crimpers
• Drill (3/32” Drill Bit)
• Phillips Head Screwdriver
• Circuit Tester

Step-by-Step Instructions:

Step 1: Locate the Taillight Wiring Harness

1. Access the vehicle's taillight wiring harness.
2. Using the provided instructions, identify the appropriate wires for connection:
   • Green Wire: Right Turn & Stop
   • Yellow Wire: Left Turn & Stop
   • Brown Wire: Taillights
   • White Wire: Ground

Step 2: Make the Electrical Connections

1. Match the color-coded wires from the wiring kit to the corresponding vehicle wires.

   • Use a circuit tester to verify each wire's function before connecting.
   • CAUTION: Test one wire at a time to prevent damage to electronic components.

2. Connect the wires using the provided insulated butt connectors:

   • Strip the ends of each wire and seat them properly in the connector.
   • Use a crimping tool designed for insulated splices to secure the connections.

3. Heat the connectors:

   • Apply heat directly to the center of each splice using a hot air gun.
   • Work from the center outward until the tubing recovers and adhesive flows.
   • Allow the connections to cool before inspecting for integrity.

Step 3: Ground the System

1. Locate a grounding point near the wiring harness, such as the vehicle frame or cross member.
   • Do not drill into the vehicle floor or bed.
2. Clean the area to remove dirt, rust, or undercoating.
3. Drill a 3/32" hole at the grounding point and secure the white wire using the provided eyelet and screw.

Step 4: Verify the Installation

1. Test all connections using a circuit tester or trailer:
   • Verify the functionality of taillights, turn signals, and brake lights.
   • Ensure all connections are complete and secure.
2. If issues are identified, double-check the wiring and connections for errors.

Step 5: Store the 4-Flat Connector

• Store the 4-flat connector in the rear cargo area when not in use to protect it from damage and environmental exposure.

Warnings and Notes:

• WARNING: Overloading a circuit can cause fires. Do not exceed the following limits:
  • Stop/Turn Lights: 7.5 amps (1 per side)
  • Tail Lights: 7.5 amps
• WARNING: Always verify what is behind any surface before drilling to avoid vehicle damage or injury.
• NOTE: Trailer lighting that requires more than 7.5 amps per circuit must use a Trailer Light Power Converter.
• NOTE: If your trailer requires a plug other than the 4-flat, consult your dealer for optional 6-way or 7-way adapters.

Maintenance:

• Inspect the wiring harness periodically for damage, corrosion, or loose connections.
• Reapply heat to connectors if the adhesive seal weakens.

Specifications:

• Maximum Load:
  • Stop/Turn Lights: 7.5 amps (1 per side)
  • Tail Lights: 7.5 amps
• Recommended Grounding Hole Size: 3/32 inches

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.

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.

Revision:

20252 Rev. A 2-6-07