Installation Instructions for Chrysler Town & Country, Dodge Grand Caravan, VW Routan, and RAM C/V Tradesman

Part Numbers:

• 90169
• 36455
• 06550

Wiring Access Location:

• SUV1, SUV2

Tools Required:

• Wrenches: 13mm, 15mm, 18mm
• Drill Bits: None

Step-by-Step Instructions:

1. Lower Exhaust:

   • Remove the bolt securing the rearmost exhaust hanger bracket to the passenger-side frame rail.
   • Retain the bolt for reinstallation.

2. Protect Air Conditioning Lines:

   • Snap the provided plastic loom into place over the air conditioning line near the bolt on the passenger side, if present.

3. Remove Existing Bolts:

   • Remove the existing bolts from the frame rails:
     • (2) on the driver side
     • (2) on the passenger side
   • Retain these bolts for hitch installation.

4. Position Hitch:

   • Raise the hitch into position, aligning it with the attachment points on the frame rails.
   • Attach the hitch using the bolts removed in Step 3. Hand tighten only.

5. Adjust Hitch Position:

   • Push the hitch toward the driver side so the passenger-side bracket rests against the trunk pan.
   • Tighten all fasteners to the torque specifications provided.

6. Reinstall Exhaust:

   • Raise the exhaust back into position and reattach the bolt removed in Step 1.
   • Rotate the exhaust hanger bracket before tightening to create additional clearance between the side bracket and the exhaust.

Torque Specifications:

• Tighten all M10 CL10.9 fasteners to 53 lb-ft (72 N*m).
• Tighten all M12 CL10.9 fasteners to 92 lb-ft (125 N*m).

Hardware List:

• (4) Existing M10 Bolts
• (2) Existing M12 Bolts
• (1) Plastic Loom (provided)

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 body panels to prevent water or exhaust fumes from entering.
• Replace any damaged hitch or ball immediately.
• Observe safety precautions when working beneath the vehicle and wear eye protection.
• Do not cut access or attachment holes with a torch.

Specifications:

• Max Gross Trailer Weight: 3,500 lb (1,589 kg)
• Max Tongue Weight: 300 lb (136 kg)
• Drawbar must be used in the RISE position only.

Additional Notes:

• Drawbar Kit: 36061 (sold separately)
• Fastener Kit: 36455F
• This product complies with V.E.S.C. Regulation V-5 and SAE J684 safety standards.

Installation Instructions for Chrysler Town & Country, Dodge Grand Caravan, VW Routan, and RAM C/V Tradesman

Part Numbers:

• 90169
• 36455
• 06550

Wiring Access Location:

• SUV1, SUV2

Tools Required:

• Wrenches: 13mm, 15mm, 18mm
• Drill Bits: None

Step-by-Step Instructions:

1. Lower Exhaust:

   • Remove the bolt securing the rearmost exhaust hanger bracket to the passenger-side frame rail.
   • Retain the bolt for reinstallation.

2. Protect Air Conditioning Lines:

   • Snap the provided plastic loom into place over the air conditioning line near the bolt on the passenger side, if present.

3. Remove Existing Bolts:

   • Remove the existing bolts from the frame rails:
     • (2) on the driver side
     • (2) on the passenger side
   • Retain these bolts for hitch installation.

4. Position Hitch:

   • Raise the hitch into position, aligning it with the attachment points on the frame rails.
   • Attach the hitch using the bolts removed in Step 3. Hand tighten only.

5. Adjust Hitch Position:

   • Push the hitch toward the driver side so the passenger-side bracket rests against the trunk pan.
   • Tighten all fasteners to the torque specifications provided.

6. Reinstall Exhaust:

   • Raise the exhaust back into position and reattach the bolt removed in Step 1.
   • Rotate the exhaust hanger bracket before tightening to create additional clearance between the side bracket and the exhaust.

Torque Specifications:

• Tighten all M10 CL10.9 fasteners to 53 lb-ft (72 N*m).
• Tighten all M12 CL10.9 fasteners to 92 lb-ft (125 N*m).

Hardware List:

• (4) Existing M10 Bolts
• (2) Existing M12 Bolts
• (1) Plastic Loom (provided)

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 body panels to prevent water or exhaust fumes from entering.
• Replace any damaged hitch or ball immediately.
• Observe safety precautions when working beneath the vehicle and wear eye protection.
• Do not cut access or attachment holes with a torch.

Specifications:

• Max Gross Trailer Weight: 3,500 lb (1,589 kg)
• Max Tongue Weight: 300 lb (136 kg)
• Drawbar must be used in the RISE position only.

Additional Notes:

• Drawbar Kit: 36061 (sold separately)
• Fastener Kit: 36455F
• This product complies with V.E.S.C. Regulation V-5 and SAE J684 safety standards.

Warranty Information:

For complete warranty instructions, please download the full installation PDF.

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.

Installation Instructions for T-Connector Adapter for Volkswagen Routan

Part Numbers:

• 118490

Tools Required:

• Trim Panel Remover
• Torx 30 Driver
• Drill (3/32” Drill Bit)
• 1/4” Socket
• Utility Knife
• Wire Cutters
• Phillips Head Screwdriver
• Test Probe

Step-by-Step Instructions:

1. Remove the Taillight Assemblies:

   • Open the tailgate and remove the vehicle’s taillight assemblies by removing the two T30 Torx head bolts on each side.
   • Carefully pry the taillight housings rearward, ensuring not to break the alignment tabs.

2. Disconnect the Driver-Side Wiring Harness:

   • Disconnect the vehicle wiring harness from the driver-side taillight socket.
   • Plug the T-Connector end with the yellow wire between the mating plugs on the driver-side taillight socket and vehicle wiring harness.
   • Ensure the connectors are clean, fully inserted, and locked in place.

3. Route the Passenger-Side T-Connector:

   • Route the harness containing the green wire down the opening behind the driver-side taillight.
   • Then, route the harness across and underneath the vehicle behind the bumper fascia and up through the opening behind the passenger-side taillight.

   Warning:

   • Avoid routing near hot pipes, heat shields, the fuel tank, or areas where the wire may be pinched or damaged.

4. Install the Passenger-Side T-Connector:

   • Repeat step 2 for the passenger-side T-Connector containing the green wire.

5. Ground the White Wire:

   • Locate a suitable grounding point near the connector, such as the vehicle’s frame or cross member.
   • Clean the area, 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. Access the Jack Storage Area:

   • Open the jack storage door, remove the jack, tools, and carpeting to access the vehicle wiring.

7. Modify the Vehicle Wiring Grommet:

   • On the driver’s side, pull the taillight wire harness and unseat the grommet.
   • Remove the grommet from the vehicle harness by untaping the tabs and slitting the grommet.

8. Route the 4-Flat Connector:

   • Route the vehicle connector and the 4-flat end through the grommet hole into the jack storage area.
   • Store the 4-flat connector in the jack storage compartment when not in use.

   Note:

   • Route the 4-flat harness through the rear tailgate/door seal when in use.
   • Be careful not to pinch the harness in the door latch.

9. Secure the Grommet:

   • Place the grommet onto the T-Connector wiring between the T-Connector and the vehicle’s mating end.
   • Retape the tabs to secure the grommet and reseat it into the vehicle hole.

10. Secure and Reassemble:

    • Secure all loose wires with cable ties.
    • Reinstall the taillight assemblies and any other items removed during installation, ensuring no wires are pinched or cut.

11. Test the Installation:

    • Test the T-Connector installation with a test light or trailer to ensure proper functionality.

    Specifications:

    • Max. stop/turn light: (7.5 amps)
    • Max. tail lights: (7.5 amps)

Safety Notes:

• Overloading circuits can cause fires. Do not exceed the towing manufacturer’s rating or the unit specifications.
• Follow all warnings and installation instructions carefully.

Manufacturer Notes:

• Refer to the vehicle owner’s manual for additional guidance.

Installation Instructions for T-Connector Adapter for Vehicle

Part Numbers:

• 118490

Tools Required:

• Trim Panel Remover
• Torx 30 Driver
• Drill (3/32” Drill Bit)
• 1/4” Socket
• Utility Knife
• Wire Cutters
• Phillips Head Screwdriver
• Test Probe

Step-by-Step Instructions:

1. Remove the Taillight Assemblies:

   • Open the tailgate and remove the vehicle’s taillight assemblies by removing the two T30 Torx head bolts on each side.
   • Carefully pry the taillight housings rearward, ensuring not to break the alignment tabs.

2. Disconnect the Driver-Side Wiring Harness:

   • Disconnect the vehicle wiring harness from the driver-side taillight socket.
   • Plug the T-Connector end with the yellow wire between the mating plugs on the driver-side taillight socket and vehicle wiring harness.
   • Ensure the connectors are clean, fully inserted, and locked in place.

3. Route the Passenger-Side T-Connector:

   • Route the harness containing the green wire down the opening behind the driver-side taillight.
   • Then, route the harness across and underneath the vehicle behind the bumper fascia and up through the opening behind the passenger-side taillight.

   Warning:

   • Avoid routing near hot pipes, heat shields, the fuel tank, or areas where the wire may be pinched or damaged.

4. Install the Passenger-Side T-Connector:

   • Repeat step 2 for the passenger-side T-Connector containing the green wire.

5. Ground the White Wire:

   • Locate a suitable grounding point near the connector, such as the vehicle’s frame or cross member.
   • Clean the area, 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. Access the Jack Storage Area:

   • Open the jack storage door, remove the jack, tools, and carpeting to access the vehicle wiring.

7. Modify the Vehicle Wiring Grommet:

   • On the driver’s side, pull the taillight wire harness and unseat the grommet.
   • Remove the grommet from the vehicle harness by untaping the tabs and slitting the grommet.

8. Route the 4-Flat Connector:

   • Route the vehicle connector and the 4-flat end through the grommet hole into the jack storage area.
   • Store the 4-flat connector in the jack storage compartment when not in use.

   Note:

   • Route the 4-flat harness through the rear tailgate/door seal when in use.
   • Be careful not to pinch the harness in the door latch.

9. Secure the Grommet:

   • Place the grommet onto the T-Connector wiring between the T-Connector and the vehicle’s mating end.
   • Retape the tabs to secure the grommet and reseat it into the vehicle hole.

10. Secure and Reassemble:

    • Secure all loose wires with cable ties.
    • Reinstall the taillight assemblies and any other items removed during installation, ensuring no wires are pinched or cut.

11. Test the Installation:

    • Test the T-Connector installation with a test light or trailer to ensure proper functionality.

    Specifications:

    • Max. stop/turn light: (7.5 amps)
    • Max. tail lights: (7.5 amps)

Safety Notes:

• Overloading circuits can cause fires. Do not exceed the towing manufacturer’s rating or the unit specifications.
• Follow all warnings and installation instructions carefully.

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:

• This product is covered by a [warranty period]. 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.

Manufacturer Notes:

• Refer to the vehicle owner’s manual for additional guidance.