Installation Instructions for Dodge Charger, Chrysler 300, Dodge Challenger (Excluding Quad Exhaust Models), and Dodge Magnum

Part Numbers:

• 36548
• 90243
• 06946

Wiring Access Location:

• PC3

Tools Required:

• Sockets: 8mm, 13mm, 15mm, 18mm, 3/4"
• Torque Wrench
• Safety Glasses
• Flat Head Screwdriver
• Plastic Trim Tools
• Ratchet
• Extension
• Universal Joint

Installation Time:

• 30 minutes: For vehicles with exhausts that separate at the rear.
• 50 minutes: For vehicles with welded exhausts and riveted exhaust tips (fascia removal required).

Step-by-Step Instructions:

Pre-2011 Models:

1. Lower Exhaust:

   • Remove two (2) exhaust hanger brackets per side using a 13mm socket.
   • Apply lubricant or soapy water to ease the removal of the metal hanger rod from the rubber isolator.

2. Prepare Weldnuts:

   • Run the M12 bolt into the existing weldnuts to clean out any debris.

3. Fishwire Hardware:

   • Fishwire 1/2" carriage bolts and spacers through the access holes on the driver and passenger side frame rails.
   • Pull the hardware through the existing holes (two on the passenger side, one on the driver side).

4. Position Hitch:

   • Slide the hitch over the mufflers and align it with the frame.
   • Loosely install the M12 bolt and conical washer (teeth side facing the hitch) into the existing weldnut.

5. Secure Fasteners:

   • Install the 1/2" conical tooth washers (teeth side facing the hitch) and 1/2" hex nuts.

6. Torque Fasteners:

   • Tighten all 1/2" fasteners to 75 ft-lb (102 N*m).
   • Tighten the M12 bolt to 68 ft-lb (92 N*m).

7. Reinstall Exhaust:

   • Reattach the exhaust hangers.

2011 and Newer Models:

1. Remove Plastic Appearance Panels:

   • For Chrysler 300/300C, remove the plastic panels covering the trunk pan. Return the panels to the vehicle owner.

2. Lower Exhaust:

   • Remove two (2) exhaust hanger brackets per side using a 13mm socket.
   • Push the muffler upward and outward to access the frame rail.

3. Remove Muffler:

   • V8 Models: Remove and save the two (2) assembly bolts and springs from the flange. Carefully remove the muffler.
   • V6 Models: Remove and save the band clamp, separate the exhaust pipes, and remove the muffler.

4. Prepare Weldnuts:

   • Run the M12 bolt into the existing weldnuts to clean out any debris.

5. Fishwire Hardware:

   • Fishwire 1/2" carriage bolts and spacers through the access holes on the driver and passenger side frame rails.
   • Pull the hardware through the existing holes (two on the passenger side, one on the driver side).

6. Install Passenger-Side Bracket:

   • Position the bracket over the passenger muffler.
   • Support the bracket and loosely install the M12 bolt and conical tooth washer through the bracket and into the frame rail.
   • Push the passenger muffler upward and outward for clearance, and install the 1/2" conical washers and hex nuts.

7. Torque Fasteners:

   • Tighten all 1/2" fasteners to 75 ft-lb (102 N*m).
   • Tighten the M12 bolt to 68 ft-lb (92 N*m).

8. Reinstall Components:

   • Reattach the exhaust hangers and reinstall wiring and fascia.

Torque Specifications:

• 1/2"-13 GR5 bolts: 75 ft-lb (102 N*m)
• M12 CL10.9 bolts: 68 ft-lb (92 N*m)

Hardware List:

• (3) Carriage Bolts, 1/2"-13 x 1.50" GR5
• (3) Spacer Blocks, 1" x 3"
• (3) Hex Nuts, 1/2"
• (4) Conical Washers, 1/2"
• (1) Hex Bolt, M12 x 1.75 x 40mm CL10.9
• (3) Fish Wires, 1/2"-13

Safety Notes:

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

Specifications:

• Max Gross Trailer Weight: 3,500 lb (1,587 kg)
• Max Tongue Weight: 300 lb (136 kg)

Additional Notes:

• Authorized Drawbar Kit: 36061 (sold separately; must be used in the RISE position only)
• Fastener Kit: 36548F
• This product complies with V.E.S.C. Regulation V-5 and SAE J684 safety standards.

Installation Instructions for Vehicles (Excluding Quad Exhaust Models)

Part Numbers:

• 36548
• 90243
• 06946

Wiring Access Location:

• PC3

Tools Required:

• Sockets: 8mm, 13mm, 15mm, 18mm, 3/4"
• Torque Wrench
• Safety Glasses
• Flat Head Screwdriver
• Plastic Trim Tools
• Ratchet
• Extension
• Universal Joint

Installation Time:

• 30 minutes: For vehicles with exhausts that separate at the rear.
• 50 minutes: For vehicles with welded exhausts and riveted exhaust tips (fascia removal required).

Step-by-Step Instructions:

Pre-2011 Models:

1. Lower Exhaust:

   • Remove two (2) exhaust hanger brackets per side using a 13mm socket.
   • Apply lubricant or soapy water to ease the removal of the metal hanger rod from the rubber isolator.

2. Prepare Weldnuts:

   • Run the M12 bolt into the existing weldnuts to clean out any debris.

3. Fishwire Hardware:

   • Fishwire 1/2" carriage bolts and spacers through the access holes on the driver and passenger side frame rails.
   • Pull the hardware through the existing holes (two on the passenger side, one on the driver side).

4. Position Hitch:

   • Slide the hitch over the mufflers and align it with the frame.
   • Loosely install the M12 bolt and conical washer (teeth side facing the hitch) into the existing weldnut.

5. Secure Fasteners:

   • Install the 1/2" conical tooth washers (teeth side facing the hitch) and 1/2" hex nuts.

6. Torque Fasteners:

   • Tighten all 1/2" fasteners to 75 ft-lb (102 N*m).
   • Tighten the M12 bolt to 68 ft-lb (92 N*m).

7. Reinstall Exhaust:

   • Reattach the exhaust hangers.

2011 and Newer Models:

1. Remove Plastic Appearance Panels:

   • For certain vehicles, remove the plastic panels covering the trunk pan. Return the panels to the vehicle owner.

2. Lower Exhaust:

   • Remove two (2) exhaust hanger brackets per side using a 13mm socket.
   • Push the muffler upward and outward to access the frame rail.

3. Remove Muffler:

   • V8 Models: Remove and save the two (2) assembly bolts and springs from the flange. Carefully remove the muffler.
   • V6 Models: Remove and save the band clamp, separate the exhaust pipes, and remove the muffler.

4. Prepare Weldnuts:

   • Run the M12 bolt into the existing weldnuts to clean out any debris.

5. Fishwire Hardware:

   • Fishwire 1/2" carriage bolts and spacers through the access holes on the driver and passenger side frame rails.
   • Pull the hardware through the existing holes (two on the passenger side, one on the driver side).

6. Install Passenger-Side Bracket:

   • Position the bracket over the passenger muffler.
   • Support the bracket and loosely install the M12 bolt and conical tooth washer through the bracket and into the frame rail.
   • Push the passenger muffler upward and outward for clearance, and install the 1/2" conical washers and hex nuts.

7. Torque Fasteners:

   • Tighten all 1/2" fasteners to 75 ft-lb (102 N*m).
   • Tighten the M12 bolt to 68 ft-lb (92 N*m).

8. Reinstall Components:

   • Reattach the exhaust hangers and reinstall wiring and fascia.

Torque Specifications:

• 1/2"-13 GR5 bolts: 75 ft-lb (102 N*m)
• M12 CL10.9 bolts: 68 ft-lb (92 N*m)

Hardware List:

• (3) Carriage Bolts, 1/2"-13 x 1.50" GR5
• (3) Spacer Blocks, 1" x 3"
• (3) Hex Nuts, 1/2"
• (4) Conical Washers, 1/2"
• (1) Hex Bolt, M12 x 1.75 x 40mm CL10.9
• (3) Fish Wires, 1/2"-13

Safety Notes:

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

Specifications:

• Max Gross Trailer Weight: 3,500 lb (1,587 kg)
• Max Tongue Weight: 300 lb (136 kg)

Additional Notes:

• Authorized Drawbar Kit: 36061 (sold separately; must be used in the RISE position only)
• Fastener Kit: 36548F
• This product complies with V.E.S.C. Regulation V-5 and SAE J684 safety standards.

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: This product is backed by a limited warranty. 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.

Installation Instructions for T-Connector Trailer Wiring Harness

Product Information:

• Part Number: N118402
• Application: Compatible vehicles

Tools Required:

• 13mm Socket & Ratchet or Wrench
• Drill with 3/32” drill bit
• Philips Head Screwdriver
• Trim Panel Remover
• Wire Crimpers
• Wire Cutters

Step-by-Step Instructions:

1. Remove the Taillight Assemblies:

   • Open the tailgate.
   • On the driver’s side, remove the two clips holding the taillight in place.
   • Inside the vehicle, remove the plastic cover and pull back the insulation liner to access the plastic wing nut holding the taillight.
   • Unscrew the wing nut and carefully pry the taillight assembly away from the vehicle.
   • Repeat for the passenger side.

2. Connect the T-Connector on the Driver’s Side:

   • Disconnect the vehicle’s wiring harness from the taillight socket.
   • Plug the T-Connector with the yellow wire between the taillight socket and the vehicle wiring harness.

3. Route the Wiring Harness:

   • Route the T-Connector end with the green wire and the 4-flat connector down through the opening between the vehicle bumper and body.
   • Route the T-Connector with the green wire to the passenger side underneath the bumper.
   • Carefully route the green wire up through the passenger-side opening and connect it to the passenger-side taillight harness.

   Warning: Avoid routing the wire near hot pipes, heat shields, the fuel tank, or any sharp edges that could pinch or damage the wire.

4. Ground the White Wire:

   • Locate a suitable grounding point near the driver-side taillight, such as the vehicle’s frame or crossmember.
   • Clean the area to remove dirt and rustproofing.
   • Drill a 3/32” hole and secure the white wire using the provided eyelet and screw.

   Caution: Ensure no damage will occur behind the surface before drilling.

5. Route the Power Wire:

   • Disconnect the vehicle’s negative battery cable.
   • If not already removed, take the fuse out of the yellow fuse holder.
   • Cut the fuse holder wire, attach the ring terminal, and secure it to the vehicle’s Positive (+) battery cable.
   • Use the provided yellow butt connector to connect the fuse holder to the black 12-gauge power wire.
   • Route the black power wire from the front of the vehicle along the frame rail to the driver’s side rear taillight area.

   Warning: Avoid contact with hot pipes, sharp edges, or moving parts.

6. Connect the Power Wire to the T-Connector Module:

   • Locate the opening near the driver’s side rear bumper.
   • Route the black 12-gauge wire up through the opening to the rear taillight area.
   • Connect the black power wire to the red wire from the T-Connector module using the yellow butt connector.

7. Reinstall the Fuse and Test the System:

   • Reconnect the vehicle’s negative battery cable.
   • Insert the 10-amp fuse into the fuse holder.
   • Test the T-Connector wiring system using a test light or by connecting a trailer. Verify the following functions:
     • Running Lights
     • Brake Lights
     • Left and Right Turn Signals

   Warning: All connections must be complete for the T-Connector to function properly.

8. Secure the T-Connector Module:

   • Behind the driver-side taillight housing, clean a flat area using a mixture of rubbing alcohol and water.
   • Mount the T-Connector’s black module box using the provided double-sided tape.

9. Secure the Wiring Harness:

   • Use the provided cable ties to secure the wiring harness, ensuring it is routed away from sharp edges, heat sources, and moving parts.

10. Reinstall Vehicle Components:

    • Reinstall the taillight housing assemblies, ensuring the wiring is not pinched.
    • Position the wiring harness between the housing and the vehicle body.
    • Mount the 4-flat connector in a suitable location under the vehicle (bracket not included).

Specifications:

• Stop/Turn Lights: 2.1 amps per side
• Taillights: 5.6 amps maximum

Safety Notes:

• Avoid overloading circuits to prevent fires or damage.
• Follow the vehicle owner’s manual for towing and electrical ratings.
• Verify all wiring functions before towing.

Warnings:

• Never route wires near hot pipes, fuel tanks, or sharp edges.
• Do not exceed the specified amperage ratings for the system.
• Improper installation may result in electrical failure or fire.

Technical Support:
For further assistance, contact the manufacturer’s technical support team.

Note: Always test the trailer wiring before use to ensure all lights function properly. Store the 4-flat connector safely when not in use.

Installation Instructions for T-Connector Trailer Wiring Harness

Product Information:

• Part Number: N118402
• Application: Compatible vehicles

Tools Required:

• 13mm Socket & Ratchet or Wrench
• Drill with 3/32” Drill Bit
• Phillips Head Screwdriver
• Trim Panel Remover
• Wire Crimpers
• Wire Cutters

Step-by-Step Instructions:

1. Remove the Taillight Assemblies:

   • Open the tailgate.
   • On the driver’s side, remove the two clips holding the taillight in place.
   • Inside the vehicle, remove the plastic cover and pull back the insulation liner to access the plastic wing nut holding the taillight.
   • Unscrew the wing nut and carefully pry the taillight assembly away from the vehicle.
   • Repeat for the passenger side.

2. Connect T-Connector on Driver’s Side:

   • Disconnect the vehicle’s wiring harness from the taillight socket.
   • Plug the T-Connector with the yellow wire between the taillight socket and the vehicle wiring harness.

3. Route the Wiring Harness:

   • Route the T-Connector end with the green wire and the 4-flat connector down through the opening between the vehicle bumper and body.
   • Route the T-Connector with the green wire to the passenger side underneath the bumper.
   • Carefully route the green wire up through the passenger-side opening and connect it to the passenger-side taillight harness.

   Warning: Avoid routing the wire near hot pipes, heat shields, the fuel tank, or any sharp edges that could pinch or damage the wire.

4. Ground the White Wire:

   • Locate a suitable grounding point near the driver-side taillight, such as the vehicle’s frame or crossmember.
   • Clean the area to remove dirt and rustproofing.
   • Drill a 3/32” hole and secure the white wire using the provided eyelet and screw.

   Caution: Ensure no damage will occur behind the surface before drilling.

5. Route the Power Wire:

   • Disconnect the vehicle’s negative battery cable.
   • If not already removed, take the fuse out of the yellow fuse holder.
   • Cut the fuse holder wire, attach the ring terminal, and secure it to the vehicle’s Positive (+) battery cable.
   • Use the provided yellow butt connector to connect the fuse holder to the black 12-gauge power wire.
   • Route the black power wire from the front of the vehicle along the frame rail to the driver’s side rear taillight area.

   Warning: Avoid contact with hot pipes, sharp edges, or moving parts.

6. Connect the Power Wire to the T-Connector Module:

   • Locate the opening near the driver’s side rear bumper.
   • Route the black 12-gauge wire up through the opening to the rear taillight area.
   • Connect the black power wire to the red wire from the T-Connector module using the yellow butt connector.

7. Reinstall the Fuse and Test the System:

   • Reconnect the vehicle’s negative battery cable.
   • Insert the 10-amp fuse into the fuse holder.
   • Test the T-Connector wiring system using a test light or by connecting a trailer. Verify the following functions:
     • Running Lights
     • Brake Lights
     • Left and Right Turn Signals

   Warning: All connections must be complete for the T-Connector to function properly.

8. Secure the T-Connector Module:

   • Behind the driver-side taillight housing, clean a flat area using a mixture of rubbing alcohol and water.
   • Mount the T-Connector’s black module box using the provided double-sided tape.

9. Secure the Wiring Harness:

   • Use the provided cable ties to secure the wiring harness, ensuring it is routed away from sharp edges, heat sources, and moving parts.

10. Reinstall Vehicle Components:

    • Reinstall the taillight housing assemblies, ensuring the wiring is not pinched.
    • Position the wiring harness between the housing and the vehicle body.
    • Mount the 4-flat connector in a suitable location under the vehicle (bracket not included).

Specifications:

• Stop/Turn Lights: 2.1 amps per side
• Taillights: 5.6 amps maximum

Safety Notes:

• Avoid overloading circuits to prevent fires or damage.
• Follow the vehicle owner’s manual for towing and electrical ratings.
• Verify all wiring functions before towing.

Warnings:

• Never route wires near hot pipes, fuel tanks, or sharp edges.
• Do not exceed the specified amperage ratings for the system.
• Improper installation may result in electrical failure or fire.

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.

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.