Installation Instructions for Chevrolet Sonic 5-Door Hatchback (All Models, Including LS, LT, LZ, & RS)

Part Numbers:

• 24878
• 60295
• 77265

Wiring Access Location:

• PC3, PC4

Tools Required:

• Wrenches/Sockets: 11/16"
• Other Tools: Socket Extension
• Drill Bits: None

Specifications:

• Max Gross Trailer Weight: 2,000 lb. (908 kg)
• Max Tongue Weight: 200 lb. (90.8 kg)
• Note: Do not exceed the towing vehicle manufacturer’s rating.

Step-by-Step Instructions:

1. Lower Exhaust:

   • Remove the three exhaust isolators on the driver’s side of the vehicle to allow the muffler to drop down.
   • The axle will keep the exhaust from falling too far.

2. Install Carriage Bolts and Blocks:

   • Use bolt leaders to feed the 7/16” carriage bolts and blocks through the larger diameter hole in the bottom of the vehicle frame and out through the smaller attachment holes.
   • Repeat for both sides of the vehicle.

3. Position Hitch:

   • Push the muffler outward and raise the hitch into position above the exhaust.
   • Locate the hitch brackets on the bottom of the frame and guide the bolts and bolt leaders through the slots in the hitch side brackets.

4. Install Fasteners:

   • Pull the ends of the carriage bolts through the vehicle frame and hitch brackets.
   • Loosely install conical toothed washers and hex nuts. Ensure the bolts engage with the square hole in the block.

5. Adjust Hitch and Secure:

   • Slide the hitch towards the passenger side of the vehicle as far as it will go.
   • Torque all 7/16”-14 GR5 carriage bolts to 50 Lb.-Ft. (68 N*M).

6. Reattach Exhaust:

   • Reinstall the exhaust isolators to secure the exhaust system.

Hardware List:

• (4) Carriage Bolts: 7/16”-14 x 1-1/2” (GR5)
• (4) Hex Nuts: 7/16” (GR2)
• (4) Blocks: 1/8” x 7/8” x 3” (with square holes)
• (4) Bolt Leaders: 7/16”
• (4) Conical Toothed Washers: 7/16”

Safety Notes:

• Regularly inspect all fasteners and the hitch ball to ensure proper tightening.
• If the hitch is removed, plug all holes in the trunk pan or body panels to prevent water and exhaust fumes from entering.
• Replace any damaged hitch or ball immediately.
• Always observe safety precautions and wear eye protection when working beneath the vehicle.
• Do not use a torch to cut access or attachment holes.

Drawbar:

• Drawbar Kit: 3590
• Important: The drawbar must be used in the rise position only.

Compliance:

• This product complies with SAE J684, V.E.S.C. Regulation V-5, and safety requirements of the State of New York.

Additional Notes:

• Check the hitch frequently to ensure all fasteners remain tight.
• Note: On RS models, there may be some deformation of the fascia.

Installation Instructions

Part Numbers:

• 24878
• 60295
• 77265

Wiring Access Location:

• PC3, PC4

Tools Required:

• Wrenches/Sockets: 11/16"
• Other Tools: Socket Extension
• Drill Bits: None

Specifications:

• Max Gross Trailer Weight: 2,000 lb. (908 kg)
• Max Tongue Weight: 200 lb. (90.8 kg)
• Note: Do not exceed the towing vehicle manufacturer’s rating.

Step-by-Step Instructions:

1. Lower Exhaust:

   • Remove the three exhaust isolators on the driver’s side of the vehicle to allow the muffler to drop down.
   • The axle will keep the exhaust from falling too far.

2. Install Carriage Bolts and Blocks:

   • Use bolt leaders to feed the 7/16” carriage bolts and blocks through the larger diameter hole in the bottom of the vehicle frame and out through the smaller attachment holes.
   • Repeat for both sides of the vehicle.

3. Position Hitch:

   • Push the muffler outward and raise the hitch into position above the exhaust.
   • Locate the hitch brackets on the bottom of the frame and guide the bolts and bolt leaders through the slots in the hitch side brackets.

4. Install Fasteners:

   • Pull the ends of the carriage bolts through the vehicle frame and hitch brackets.
   • Loosely install conical toothed washers and hex nuts. Ensure the bolts engage with the square hole in the block.

5. Adjust Hitch and Secure:

   • Slide the hitch towards the passenger side of the vehicle as far as it will go.
   • Torque all 7/16”-14 GR5 carriage bolts to 50 Lb.-Ft. (68 N*M).

6. Reattach Exhaust:

   • Reinstall the exhaust isolators to secure the exhaust system.

Hardware List:

• (4) Carriage Bolts: 7/16”-14 x 1-1/2” (GR5)
• (4) Hex Nuts: 7/16” (GR2)
• (4) Blocks: 1/8” x 7/8” x 3” (with square holes)
• (4) Bolt Leaders: 7/16”
• (4) Conical Toothed Washers: 7/16”

Safety Notes:

• Regularly inspect all fasteners and the hitch ball to ensure proper tightening.
• If the hitch is removed, plug all holes in the trunk pan or body panels to prevent water and exhaust fumes from entering.
• Replace any damaged hitch or ball immediately.
• Always observe safety precautions and wear eye protection when working beneath the vehicle.
• Do not use a torch to cut access or attachment holes.

Drawbar:

• Drawbar Kit: 3590
• Important: The drawbar must be used in the rise position only.

Compliance:

• This product complies with SAE J684, V.E.S.C. Regulation V-5, and safety requirements of the State of New York.

Additional Notes:

• Check the hitch frequently to ensure all fasteners remain tight.
• Note: On RS models, there may be some deformation of the fascia.

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.

For 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.