Installation Instructions for Hyundai Sonata (2011-Current) and Kia Optima (2011-Current)

Part Numbers:

• 24965
• 77965
• CQT24965

Tools Required:

• Ratchet
• Torque Wrench
• Safety Glasses
• Sockets: 10mm, 11/16", 12mm, 13mm
• 6” Socket Extension
• Phillips Screwdriver
• Flat Head Screwdriver
• Exhaust Removal Pliers
• Tape Measure
• Tin Snips
• Utility Knife
• Ratchet Strap or Bungee Cord
• Soapy Water or Lubricant

Step-by-Step Instructions:

1. Lower Mufflers:

   • Remove the rearmost rubber hangers and the rubber hanger near the rear axle using exhaust removal pliers.
   • Spray lubricant on hangers to ease removal.
   • Support the exhaust before removing hangers.

2. Remove Factory Muffler Hanger Brackets:

   • Remove two hex nuts per hanger bracket and return brackets and fasteners to the vehicle owner.

3. Remove Driver-Side Plastic Panel:

   • Remove and return the panel to the vehicle owner or trim it as specified in Figure 10.

4. Remove Rear Plastic Panel:

   • Remove the panel covering the space between the bumper fascia and trunk pan and return it to the vehicle owner.

5. Remove Heat Shields:

   • Remove 3–5 hex nuts per shield to detach.
   • Trim heat shields as required (see Figures 7–9) and reinstall them later.

6. Install Rear Fasteners:

   • Use the pull wires provided to install 7/16 x 1.50" carriage bolts and special washers through 7/8" holes in the frame, pulling them through 3/4" rearward holes.

7. Install Forward Fasteners:

   • Use the pull wires provided to install 7/16 x 1.25" carriage bolts and spacer blocks through the same 7/8" holes.

8. Reinstall Heat Shields:

   • Attach the trimmed heat shields using the original fasteners.

9. Raise Hitch into Position:

   • Attach 7/16" conical toothed washers and hex nuts to the forward bolts.
   • Use spacer blocks and flat washers if necessary to level the hitch with the vehicle frame.
   • Tighten all 7/16-14 fasteners to 50 lb-ft (68 N*m).

10. Trim Fascia:

    • Trim a small notch in the fascia at the rear edge of the hitch bracket as needed.

11. Raise Mufflers:

    • Reattach all rubber hangers removed earlier.

12. Reinstall Plastic Panels:

    • Reinstall the driver-side and rear panels if trimming was done.

Hardware List:

• (2) Carriage Bolt, 7/16-14 x 1.25" GR5
• (2) Carriage Bolt, 7/16-14 x 1.50" GR5
• (2) Special Washer, .109 x .88 x 2.0 (Part No. 1204)
• (2) Spacer Block, 3/16 x 1.50 x 2.00 (Part No. 04833001)
• (4) Conical Washer, 7/16 (Part No. 01292007)
• (4) Hex Nut, 7/16-14 GR2
• (4) Flat Washer, 7/16 (used as spacers on some models)
• (4) Pull Wire, 7/16

Safety Notes:

• Always wear safety glasses during installation.
• Check hitch and fasteners frequently to ensure they remain securely tightened.
• Replace any damaged hitch or ball immediately.
• Plug all removed holes to prevent water or exhaust fume entry.
• Do not exceed the vehicle manufacturer’s towing ratings:
  • Max Gross Trailer Weight: 2,000 lb (908 kg)
  • Max Tongue Weight: 200 lb (90.8 kg)

Specifications:

• Installation Time: 40 minutes
• Complies with SAE J684 and VESC Regulation V-5 standards.

Installation Instructions for Vehicle (2011-Current)

Part Numbers:

• 24965
• 77965
• CQT24965

Tools Required:

• Ratchet
• Torque Wrench
• Safety Glasses
• Sockets: 10mm, 11/16", 12mm, 13mm
• 6” Socket Extension
• Phillips Screwdriver
• Flat Head Screwdriver
• Exhaust Removal Pliers
• Tape Measure
• Tin Snips
• Utility Knife
• Ratchet Strap or Bungee Cord
• Soapy Water or Lubricant

Step-by-Step Instructions:

1. Lower Mufflers:

   • Remove the rearmost rubber hangers and the rubber hanger near the rear axle using exhaust removal pliers.
   • Spray lubricant on hangers to ease removal.
   • Support the exhaust before removing hangers.

2. Remove Factory Muffler Hanger Brackets:

   • Remove two hex nuts per hanger bracket and return brackets and fasteners to the vehicle owner.

3. Remove Driver-Side Plastic Panel:

   • Remove and return the panel to the vehicle owner or trim it as specified in Figure 10.

4. Remove Rear Plastic Panel:

   • Remove the panel covering the space between the bumper fascia and trunk pan and return it to the vehicle owner.

5. Remove Heat Shields:

   • Remove 3–5 hex nuts per shield to detach.
   • Trim heat shields as required (see Figures 7–9) and reinstall them later.

6. Install Rear Fasteners:

   • Use the pull wires provided to install 7/16 x 1.50" carriage bolts and special washers through 7/8" holes in the frame, pulling them through 3/4" rearward holes.

7. Install Forward Fasteners:

   • Use the pull wires provided to install 7/16 x 1.25" carriage bolts and spacer blocks through the same 7/8" holes.

8. Reinstall Heat Shields:

   • Attach the trimmed heat shields using the original fasteners.

9. Raise Hitch into Position:

   • Attach 7/16" conical toothed washers and hex nuts to the forward bolts.
   • Use spacer blocks and flat washers if necessary to level the hitch with the vehicle frame.
   • Tighten all 7/16-14 fasteners to 50 lb-ft (68 N*m).

10. Trim Fascia:

    • Trim a small notch in the fascia at the rear edge of the hitch bracket as needed.

11. Raise Mufflers:

    • Reattach all rubber hangers removed earlier.

12. Reinstall Plastic Panels:

    • Reinstall the driver-side and rear panels if trimming was done.

Hardware List:

• (2) Carriage Bolt, 7/16-14 x 1.25" GR5
• (2) Carriage Bolt, 7/16-14 x 1.50" GR5
• (2) Special Washer, .109 x .88 x 2.0 (Part No. 1204)
• (2) Spacer Block, 3/16 x 1.50 x 2.00 (Part No. 04833001)
• (4) Conical Washer, 7/16 (Part No. 01292007)
• (4) Hex Nut, 7/16-14 GR2
• (4) Flat Washer, 7/16 (used as spacers on some models)
• (4) Pull Wire, 7/16

Safety Notes:

• Always wear safety glasses during installation.
• Check hitch and fasteners frequently to ensure they remain securely tightened.
• Replace any damaged hitch or ball immediately.
• Plug all removed holes to prevent water or exhaust fume entry.
• Do not exceed the vehicle manufacturer’s towing ratings:
  • Max Gross Trailer Weight: 2,000 lb (908 kg)
  • Max Tongue Weight: 200 lb (90.8 kg)

Specifications:

• Installation Time: 40 minutes
• Complies with SAE J684 and VESC Regulation V-5 standards.

Additional Information:

• 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.

Warranty:

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

Installation Instructions for T-Connector Adapter for Hyundai Sonata

Part Numbers:

• 118557

Tools Required:

• Trim Panel Remover
• Drill (3/32” Drill Bit)
• Phillips Head Screwdriver
• Test Probe

Step-by-Step Instructions:

1. Open the Trunk and Remove Panels:

   • Open the trunk and temporarily remove the rear threshold plate.
   • Partially remove the felt trunk liner behind the taillights.

2. Locate the Vehicle’s Taillight Wiring Harness:

   • On both the driver’s and passenger’s sides, locate the taillight wiring harness.
   • Disconnect the connectors carefully, ensuring not to break the locking tabs. Ensure all connector surfaces are clean and free of dirt.

3. Connect the Driver-Side T-Connector:

   • Insert the T-Connector end with the yellow wire between the driver’s side wiring connectors.
   • Ensure all connectors are fully inserted with locking tabs secure.

4. Route the Passenger-Side T-Connector:

   • Route the T-Connector with the green wire behind the panels and along the threshold to the passenger side.
   • Repeat step 3 for the passenger side, connecting the green wire.

5. Ground the White Wire:

   • Locate a suitable grounding point near the connector.
   • Clean dirt and rustproofing from the area.
   • 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. Do not drill into exposed surfaces.

6. Connect the Power Wire:

   • Inside the vehicle, connect the black 12-gauge wire and the red wire from the T-Connector black box using the supplied yellow butt connector.
   • Route the black wire through a grommet or along the thresholds to the engine compartment up to the battery.

   Warning:

   • Avoid routing the wire near hot pipes, heat shields, fuel tanks, or any areas that may pinch or damage the wire.

7. Connect to the Vehicle Battery:

   • Disconnect the vehicle’s negative (-) battery cable.
   • Attach the ring terminal to the positive (+) battery cable and connect the other end of the fuse holder to the black wire using the yellow butt connector.

8. Install the Fuse:

   • Insert the 10-amp fuse into the fuse holder.
   • Reconnect the vehicle’s negative (-) battery cable.

9. Mount the Black Box:

   • Mount the T-Connector black box on a flat, out-of-the-way surface inside the vehicle using the provided double-sided tape.

10. Secure the Wiring:

    • Use the provided cable ties to secure the remaining T-Connector harness, ensuring wires are not pinched, cut, or damaged.

11. Reassemble the Vehicle:

    • Reinstall the trunk panels, threshold, and other items removed during installation.

12. Test the Installation:

    • Test and verify the T-Connector installation with a test light or trailer.

    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 specified maximum circuit ratings.
• Always follow installation instructions and safety precautions.

Manufacturer Notes:

• Refer to the vehicle owner’s manual and instruction sheet for additional details.
• Store the 4-flat connector in the trunk when not in use.

Installation Instructions for T-Connector Adapter for Hyundai Sonata

Part Numbers:

• 118557

Tools Required:

• Trim Panel Remover
• Drill (3/32” Drill Bit)
• Phillips Head Screwdriver
• Test Probe

Step-by-Step Instructions:

1. Open the Trunk and Remove Panels:

   • Open the trunk and temporarily remove the rear threshold plate.
   • Partially remove the felt trunk liner behind the taillights.

2. Locate the Vehicle’s Taillight Wiring Harness:

   • On both the driver’s and passenger’s sides, locate the taillight wiring harness.
   • Disconnect the connectors carefully, ensuring not to break the locking tabs. Ensure all connector surfaces are clean and free of dirt.

3. Connect the Driver-Side T-Connector:

   • Insert the T-Connector end with the yellow wire between the driver’s side wiring connectors.
   • Ensure all connectors are fully inserted with locking tabs secure.

4. Route the Passenger-Side T-Connector:

   • Route the T-Connector with the green wire behind the panels and along the threshold to the passenger side.
   • Repeat step 3 for the passenger side, connecting the green wire.

5. Ground the White Wire:

   • Locate a suitable grounding point near the connector.
   • Clean dirt and rustproofing from the area.
   • 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. Do not drill into exposed surfaces.

6. Connect the Power Wire:

   • Inside the vehicle, connect the black 12-gauge wire and the red wire from the T-Connector black box using the supplied yellow butt connector.
   • Route the black wire through a grommet or along the thresholds to the engine compartment up to the battery.

   Warning:

   • Avoid routing the wire near hot pipes, heat shields, fuel tanks, or any areas that may pinch or damage the wire.

7. Connect to the Vehicle Battery:

   • Disconnect the vehicle’s negative (-) battery cable.
   • Attach the ring terminal to the positive (+) battery cable and connect the other end of the fuse holder to the black wire using the yellow butt connector.

8. Install the Fuse:

   • Insert the 10-amp fuse into the fuse holder.
   • Reconnect the vehicle’s negative (-) battery cable.

9. Mount the Black Box:

   • Mount the T-Connector black box on a flat, out-of-the-way surface inside the vehicle using the provided double-sided tape.

10. Secure the Wiring:

    • Use the provided cable ties to secure the remaining T-Connector harness, ensuring wires are not pinched, cut, or damaged.

11. Reassemble the Vehicle:

    • Reinstall the trunk panels, threshold, and other items removed during installation.

12. Test the Installation:

    • Test and verify the T-Connector installation with a test light or trailer.

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 specified maximum circuit ratings.
• Always follow installation instructions and safety precautions.

Manufacturer Notes:

• Refer to the vehicle owner’s manual and instruction sheet for additional details.
• Store the 4-flat connector in the trunk when not in use.

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 Information:

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

Caution: Improper installation or circuit overloads can cause electrical failures. Always follow instructions carefully and test the installation thoroughly before use.