Installation Instructions for Toyota Camry and Toyota Avalon

Part Numbers:

• 36540
• 90031
• 06160

Wiring Access Location:

• PC3, PC4

Tools Required:

• Wrenches: 10mm, 12mm, 14mm, 17mm, 11/16"
• Drill Bits: 1/4", 1", 1/2"
• Utility Knife
• Lubricant or Soapy Water

Step-by-Step Instructions:

1. Remove Appearance Panel:

   • Remove the appearance panel from the driver's side frame rails. Trim or remove the panel based on the vehicle model. Obtain the vehicle owner's approval before trimming.

2. Lower Exhaust:

   • Remove two bolts from the exhaust hanger bracket and detach the rubber isolator on the forward side of the exhaust. Spray lubricant or soapy water on the hanger rod and rubber isolator for easier removal.
   • Leave rubber isolators attached to the exhaust hanger bracket. For dual exhaust models, repeat this step on both sides.

3. Remove Heat Shields:

   • Remove the heat shields and set them aside.

4. Position Hitch:

   • Slide the hitch into position over the exhaust pipes and install M10 hex bolts for temporary support. Note:
     • For hybrid models, remove the rearmost bolt from the battery bracket on the passenger side and attach the hitch using the supplied M8 x 40mm hex bolt. Drilling is required on the driver side.

5. Drill Holes:

   • Use the hitch as a template to mark and center punch the holes on both sides. Drill 1/4" pilot holes first, followed by 1" access holes in the frame rail. Mark and drill the heat shield for the 7/16" carriage bolt.

6. Insert Fasteners:

   • Insert the carriage bolt and spacer into the frame as shown, leaving the pull wire attached.

7. Reinstall Hitch:

   • Raise the hitch into position, threading the pull wire through the bracket. Install M10 bolts on both sides. Remove the pull wire and install conical washers and nuts.

8. Secure Forward Brackets:

   • Install exhaust hanger brackets on both sides through the forward weld nut. Bend the tab on the exhaust hanger to allow the bracket to lay flat on the hitch bracket.

9. Reinstall Heat Shields:

   • Attach the heat shields using the M6 bolts provided.

10. Raise Exhaust:

    • Reinstall the exhaust system and secure with the rubber isolators.

11. Tighten Fasteners:

    • Torque all fasteners to the specified values:
      • Tighten all 7/16"-14 GR5 fasteners to 50 lb-ft (68 N*m).
      • Tighten all M8-1.25 CL10.9 fasteners to 27 lb-ft (37 N*m).
      • Tighten all M10-1.25 CL8.8 fasteners to 38 lb-ft (52 N*m).

Hardware List:

• (4) Hex Bolt, M10 x 1.25 x 40mm CL8.8
• (2) Carriage Bolt, 7/16"-14 x 1.5" GR5
• (2) Hex Bolt, M8 x 1.25 x 50mm CL10.9
• (2) Hex Bolt, M6 x 1.0 x 40mm
• (2) Conical Washer, 7/16"
• (5) Conical Washer, 3/8"
• (2) Spacer Block, .915" x 3.000" x 10GA
• (2) Hex Nut, 7/16"-14

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)

Additional Notes:

• Drawbar Kit: 36071 (sold separately)
• Fastener Kit: 36540F
• This product complies with V.E.S.C. Regulation V-5 and SAE J684 safety standards.

Installation Instructions for Toyota Camry and Toyota Avalon

Part Numbers:

• 36540
• 90031
• 06160

Wiring Access Location:

• PC3, PC4

Tools Required:

• Wrenches: 10mm, 12mm, 14mm, 17mm, 11/16"
• Drill Bits: 1/4", 1", 1/2"
• Utility Knife
• Lubricant or Soapy Water

Step-by-Step Instructions:

1. Remove Appearance Panel:

   • Remove the appearance panel from the driver's side frame rails. Trim or remove the panel based on the vehicle model. Obtain the vehicle owner's approval before trimming.

2. Lower Exhaust:

   • Remove two bolts from the exhaust hanger bracket and detach the rubber isolator on the forward side of the exhaust. Spray lubricant or soapy water on the hanger rod and rubber isolator for easier removal.
   • Leave rubber isolators attached to the exhaust hanger bracket. For dual exhaust models, repeat this step on both sides.

3. Remove Heat Shields:

   • Remove the heat shields and set them aside.

4. Position Hitch:

   • Slide the hitch into position over the exhaust pipes and install M10 hex bolts for temporary support. Note:
     • For hybrid models, remove the rearmost bolt from the battery bracket on the passenger side and attach the hitch using the supplied M8 x 40mm hex bolt. Drilling is required on the driver side.

5. Drill Holes:

   • Use the hitch as a template to mark and center punch the holes on both sides. Drill 1/4" pilot holes first, followed by 1" access holes in the frame rail. Mark and drill the heat shield for the 7/16" carriage bolt.

6. Insert Fasteners:

   • Insert the carriage bolt and spacer into the frame as shown, leaving the pull wire attached.

7. Reinstall Hitch:

   • Raise the hitch into position, threading the pull wire through the bracket. Install M10 bolts on both sides. Remove the pull wire and install conical washers and nuts.

8. Secure Forward Brackets:

   • Install exhaust hanger brackets on both sides through the forward weld nut. Bend the tab on the exhaust hanger to allow the bracket to lay flat on the hitch bracket.

9. Reinstall Heat Shields:

   • Attach the heat shields using the M6 bolts provided.

10. Raise Exhaust:

    • Reinstall the exhaust system and secure with the rubber isolators.

11. Tighten Fasteners:

    • Torque all fasteners to the specified values:
      • Tighten all 7/16"-14 GR5 fasteners to 50 lb-ft (68 N*m).
      • Tighten all M8-1.25 CL10.9 fasteners to 27 lb-ft (37 N*m).
      • Tighten all M10-1.25 CL8.8 fasteners to 38 lb-ft (52 N*m).

Hardware List:

• (4) Hex Bolt, M10 x 1.25 x 40mm CL8.8
• (2) Carriage Bolt, 7/16"-14 x 1.5" GR5
• (2) Hex Bolt, M8 x 1.25 x 50mm CL10.9
• (2) Hex Bolt, M6 x 1.0 x 40mm
• (2) Conical Washer, 7/16"
• (5) Conical Washer, 3/8"
• (2) Spacer Block, .915" x 3.000" x 10GA
• (2) Hex Nut, 7/16"-14

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)

Additional Notes:

• Drawbar Kit: 36071 (sold separately)
• Fastener Kit: 36540F
• 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

Part Numbers:

• 118405

Wiring Access Location:

• Rear taillight assemblies and under the vehicle near the bumper.

Tools Required:

• Drill with 3/32” drill bit.
• Philips head screwdriver.
• 10mm socket and ratchet or wrench.
• Wire crimpers and cutters.
• Trim panel remover.

Step-by-Step Instructions:

1. Access Vehicle Wiring:

   • Open the rear tailgate and remove the threshold panel.
   • For Mazda 6 Sedan and Coupe, remove the two 10mm nuts securing the driver’s side taillight housing. Pull the housing directly rearward to remove and set aside.

2. Prepare Wiring for Mazda 6 and Toyota Camry:

   • Locate the vehicle's wiring inside the trunk area by removing the plastic threshold cover and trunk liner.
   • Route the black 12-gauge wire through the opening in the taillight socket and behind the bumper to the engine compartment.

3. Driver’s Side Connection:

   • Attach the T-Connector containing the yellow and red wires between the vehicle wiring connectors behind the driver’s side taillight. Ensure the connectors are fully inserted and secure the locking tabs.

4. Passenger’s Side Connection:

   • Route the T-Connector with the green wire to the passenger side beneath the vehicle threshold cover.
   • Repeat step 3 using the T-Connector ends with the green wire.

5. Ground Connection:

   • Locate a suitable grounding point near the connector:
     • Option 1: Clean the area, drill a 3/32” hole, and secure the white wire with the provided eyelet and screw.
     • Option 2: Use an existing ground stud. Loosen the bolt, attach the eyelet, and retighten.

6. Routing the Power Wire:

   • Route the black 12-gauge wire from the taillight area to the engine compartment, avoiding hot pipes, heat shields, and the fuel tank.

7. Connect to the Battery:

   • Disconnect the negative battery cable.
   • Install the yellow fuse holder on the positive battery cable using the provided ring terminal and yellow butt connector.
   • Connect the other end of the fuse holder to the black 12-gauge wire using the provided yellow butt connector.

8. Reconnect Battery and Test Installation:

   • Reconnect the negative battery cable.
   • Insert the 10-amp fuse into the fuse holder.
   • Test the installation with a test light or trailer.

9. Final Steps:

   • Secure the T-Connector black box using the provided double-sided tape.
   • Use cable ties to secure the remaining harness to prevent damage or rattling.
   • Reinstall all panels, liners, and covers removed during the process.

   Specifications:

   • Max. stop/turn light: 1 per side (2.1 amps).
   • Max. tail lights: (4.2 amps).

Hardware List:

• T-Connector adapter.
• Black converter box.
• Yellow fuse holder with 10-amp fuse.
• Eyelet and screw.
• Double-sided tape.
• Cable ties.

Safety Notes:

• Ensure all connections are complete to avoid circuit overload.
• Test thoroughly after installation to confirm functionality.

Manufacturer Notes:

• Follow all vehicle warnings and installation instructions.
• Use a test light or trailer to confirm proper installation.
• Consult the vehicle owner’s manual for additional details.

Installation Instructions for T-Connector Adapter

Part Numbers:

• 118405

Wiring Access Location:

• Rear taillight assemblies and under the vehicle near the bumper.

Tools Required:

• Drill with 3/32” drill bit
• Philips head screwdriver
• 10mm socket and ratchet or wrench
• Wire crimpers and cutters
• Trim panel remover

Step-by-Step Instructions:

1. Access Vehicle Wiring:

   • Open the rear tailgate and remove the threshold panel.
   • For Mazda 6 Sedan and Coupe, remove the two 10mm nuts securing the driver’s side taillight housing. Pull the housing directly rearward to remove and set aside.

2. Prepare Wiring for Mazda 6 and Toyota Camry:

   • Locate the vehicle's wiring inside the trunk area by removing the plastic threshold cover and trunk liner.
   • Route the black 12-gauge wire through the opening in the taillight socket and behind the bumper to the engine compartment.

3. Driver’s Side Connection:

   • Attach the T-Connector containing the yellow and red wires between the vehicle wiring connectors behind the driver’s side taillight.
   • Ensure the connectors are fully inserted and secure the locking tabs.

4. Passenger’s Side Connection:

   • Route the T-Connector with the green wire to the passenger side beneath the vehicle threshold cover.
   • Repeat step 3 using the T-Connector ends with the green wire.

5. Ground Connection:

   • Locate a suitable grounding point near the connector:
     • Option 1: Clean the area, drill a 3/32” hole, and secure the white wire with the provided eyelet and screw.
     • Option 2: Use an existing ground stud. Loosen the bolt, attach the eyelet, and retighten.

6. Routing the Power Wire:

   • Route the black 12-gauge wire from the taillight area to the engine compartment, avoiding hot pipes, heat shields, and the fuel tank.

7. Connect to the Battery:

   • Disconnect the negative battery cable.
   • Install the yellow fuse holder on the positive battery cable using the provided ring terminal and yellow butt connector.
   • Connect the other end of the fuse holder to the black 12-gauge wire using the provided yellow butt connector.

8. Reconnect Battery and Test Installation:

   • Reconnect the negative battery cable.
   • Insert the 10-amp fuse into the fuse holder.
   • Test the installation with a test light or trailer.

9. Final Steps:

   • Secure the T-Connector black box using the provided double-sided tape.
   • Use cable ties to secure the remaining harness to prevent damage or rattling.
   • Reinstall all panels, liners, and covers removed during the process.

Specifications:

• Max. stop/turn light: 1 per side (2.1 amps)
• Max. tail lights: (4.2 amps)

Hardware List:

• T-Connector adapter
• Black converter box
• Yellow fuse holder with 10-amp fuse
• Eyelet and screw
• Double-sided tape
• Cable ties

Safety Notes:

• Ensure all connections are complete to avoid circuit overload.
• Test thoroughly after installation to confirm functionality.

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.