Installation Instructions for Dodge Sprinter, Mercedes Sprinter, and Freightliner Sprinter (with Factory Step Bumper)

Part Numbers:

• 44591
• 75601
• 87456

Tools Required:

• Wrenches: 18mm, 19mm
• Drill Bits: None

Wiring Access Location:

• SUV1, SUV2

Step-by-Step Instructions:

1. Prepare Bumper Mounting Bolts:

   • Remove all nuts from the existing bumper mounting bolts (3 per side). Do not remove the bolts yet.
   • If the bumper mounting bolts are pointing inboard, turn each bolt one at a time so they point outboard, ensuring the bolt heads are flush with the outboard side of the frame rails.
   • Note: Turning bolts one at a time prevents the bumper from falling.

2. Position the Hitch:

   • Raise the hitch into position.
   • Push the bumper mounting bolts the rest of the way through the hitch brackets.

3. Secure Hitch with Fasteners:

   • Reinstall the flange nuts removed in Step 1.
   • Install the additional bolts as shown in the diagram:
     • Insert M12 bolts, lock washers, spacers, and nuts on both sides.

4. Tighten Fasteners:

   • Use a torque wrench to tighten all M12 fasteners to 68 lb-ft (92 N·m).

Hardware List:

• (2) M12 x 1.75 x 120mm CL8.8 Hex Bolts
• (2) 1/2" Lock Washers
• (2) 7/16" x 1" x 2" Spacers
• (2) M12 x 1.75 Hex Nuts

Safety Notes:

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

Specifications:

• Hitch Type and Weight Ratings:
  • Weight Carrying (Ball Mount): Max Trailer Weight 5,000 lbs (2,270 kg), Max Tongue Weight 500 lbs (227 kg).
  • Weight Distributing: Max Trailer Weight 7,500 lbs (3,405 kg), Max Tongue Weight 750 lbs (341 kg).
• Complies with safety specifications and requirements for connecting devices and towing systems of the State of New York, V.E.S.C. Regulation V-5, and SAE J684.

Additional Note:

• This hitch will not fit vehicles with a 30-3/8" frame width measured outside-to-outside.

Installation Instructions for Vehicles (Generic)
(With Factory Step Bumper)

Part Numbers:

• 44591
• 75601
• 87456

Tools Required:

• Wrenches: 18mm, 19mm
• Drill Bits: None

Wiring Access Location:

• SUV1, SUV2

Step-by-Step Instructions:

1. Prepare Bumper Mounting Bolts:

   • Remove all nuts from the existing bumper mounting bolts (3 per side). Do not remove the bolts yet.
   • If the bumper mounting bolts are pointing inboard, turn each bolt one at a time so they point outboard, ensuring the bolt heads are flush with the outboard side of the frame rails.
   • Note: Turning bolts one at a time prevents the bumper from falling.

2. Position the Hitch:

   • Raise the hitch into position.
   • Push the bumper mounting bolts the rest of the way through the hitch brackets.

3. Secure Hitch with Fasteners:

   • Reinstall the flange nuts removed in Step 1.
   • Install the additional bolts as shown in the diagram:
     • Insert M12 bolts, lock washers, spacers, and nuts on both sides.

4. Tighten Fasteners:

   • Use a torque wrench to tighten all M12 fasteners to 68 lb-ft (92 N·m).

Hardware List:

• (2) M12 x 1.75 x 120mm CL8.8 Hex Bolts
• (2) 1/2" Lock Washers
• (2) 7/16" x 1" x 2" Spacers
• (2) M12 x 1.75 Hex Nuts

Safety Notes:

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

Warranty Information:

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

Specifications:

• Hitch Type and Weight Ratings:
  • Weight Carrying (Ball Mount): Max Trailer Weight 5,000 lbs (2,270 kg), Max Tongue Weight 500 lbs (227 kg).
  • Weight Distributing: Max Trailer Weight 7,500 lbs (3,405 kg), Max Tongue Weight 750 lbs (341 kg).
• Complies with safety specifications and requirements for connecting devices and towing systems.

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.

Additional Note:

• This hitch will not fit vehicles with a 30-3/8" frame width measured outside-to-outside.

Installation Instructions for T-One® T-Connector for Mercedes Sprinter

Part Numbers:

• 118649

Tools Required:

• Trim Panel Remover
• 10mm Socket & Ratchet or Wrench
• Drill (3/32” Drill Bit)
• 1/4” Socket
• Wire Crimpers
• Wire Cutters
• Phillips Head Screwdriver
• Test Probe
• Torx 25 Driver
• Torx 30 Driver

Step-by-Step Instructions:

1. Open Rear Doors and Access Taillights:

   • Locate the plastic covers that shield the rear taillights on each side of the vehicle.
   • Using a trim panel remover, carefully remove the three covers on each side. The first cover exposes the taillight harness; the upper covers assist with wire routing.

2. Disconnect the Wiring Harness:

   • On both sides, locate the vehicle’s taillight wiring harness.
   • Disconnect the harness connectors, ensuring the locking tabs remain intact.
   • Clean all connector surfaces to ensure proper connection.

3. Install the T-One® T-Connector Black Box:

   • Find a flat surface near the taillight area inside the vehicle.
   • Mount the black box module to prevent damage or rattling.

4. Connect the Driver-Side T-Connector:

   • Insert the T-Connector end with the yellow wire between the driver-side vehicle wiring connectors.
   • Ensure all connectors are fully inserted and locked securely.

5. Route the Passenger-Side T-Connector:

   • Route the T-Connector end with the green wire through the inner channel to the roof area of the vehicle.
   • Follow existing wiring across to the passenger side and conceal the wire behind plastic wire covers where possible.
   • Secure the wiring to existing harnesses using the provided cable ties.

6. Connect the Passenger-Side T-Connector:

   • Route the wires down through the openings exposed earlier.
   • Connect the T-Connector end with the green wire to the passenger-side wiring harness.

7. Ground the White Wire:

   • Locate a grounding point near the driver-side connector.
   • Clean the area to remove dirt and rustproofing.
   • Drill a 3/32” hole and secure the white wire with the provided eyelet and screw.

   Caution:

   • Verify the area behind before drilling to avoid damage or injury.

8. Connect the Power Wire:

   • From inside the vehicle, connect the black 12-gauge wire to the black wire from the T-One® black box using the yellow butt connector.
   • Route the black wire through the channel to the roof area, following existing wiring toward the driver's seat.
   • Conceal the wire behind plastic wire covers where possible.

9. Route the Wire to the Battery:

   • Continue routing the black wire behind the trim panel next to the driver's seat and along the vehicle floor.
   • Access the battery compartment beneath the driver-side floor.
   • Remove the screws holding the threshold and floor coverings, then expose the battery.

10. Connect to the Vehicle Battery:

    • Disconnect the negative (-) battery cable.
    • Attach the provided fuse holder to the positive (+) battery terminal using the provided ring terminal.
    • Connect the other end of the fuse holder to the black wire with the yellow butt connector.
    • Insert the 15-amp fuse into the fuse holder.

    Warning:

    • Follow all warnings and instructions for handling the vehicle battery.

11. Reconnect the Battery:

    • Reconnect the negative (-) battery cable.
    • Test the installation with a test light or trailer to ensure proper operation.

12. Secure and Reassemble:

    • Use cable ties to secure the remaining harness.
    • Replace all trim panels, covers, and components removed during installation, ensuring no wires are pinched or damaged.

13. Store the 4-Flat Connector:

    • Store the 4-flat connector in the vehicle's cargo area when not in use.

Specifications:

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

Safety Notes:

• Overloading circuits can cause fires. Do not exceed stated ratings or manufacturer specifications.
• Always wear safety glasses and follow safety precautions during installation.

Manufacturer Notes:

• Refer to the vehicle owner’s manual and instruction sheet for additional details.
• Store these instructions for future reference.

Installation Instructions for T-One® T-Connector for Mercedes Sprinter

Part Numbers:

• 118649

Tools Required:

• Trim Panel Remover
• 10mm Socket & Ratchet or Wrench
• Drill (3/32” Drill Bit)
• 1/4” Socket
• Wire Crimpers
• Wire Cutters
• Phillips Head Screwdriver
• Test Probe
• Torx 25 Driver
• Torx 30 Driver

Step-by-Step Instructions:

1. Open Rear Doors and Access Taillights:

   • Locate the plastic covers that shield the rear taillights on each side of the vehicle.
   • Using a trim panel remover, carefully remove the three covers on each side. The first cover exposes the taillight harness; the upper covers assist with wire routing.

2. Disconnect the Wiring Harness:

   • On both sides, locate the vehicle’s taillight wiring harness.
   • Disconnect the harness connectors, ensuring the locking tabs remain intact.
   • Clean all connector surfaces to ensure proper connection.

3. Install the T-One® T-Connector Black Box:

   • Find a flat surface near the taillight area inside the vehicle.
   • Mount the black box module to prevent damage or rattling.

4. Connect the Driver-Side T-Connector:

   • Insert the T-Connector end with the yellow wire between the driver-side vehicle wiring connectors.
   • Ensure all connectors are fully inserted and locked securely.

5. Route the Passenger-Side T-Connector:

   • Route the T-Connector end with the green wire through the inner channel to the roof area of the vehicle.
   • Follow existing wiring across to the passenger side and conceal the wire behind plastic wire covers where possible.
   • Secure the wiring to existing harnesses using the provided cable ties.

6. Connect the Passenger-Side T-Connector:

   • Route the wires down through the openings exposed earlier.
   • Connect the T-Connector end with the green wire to the passenger-side wiring harness.

7. Ground the White Wire:

   • Locate a grounding point near the driver-side connector.
   • Clean the area to remove dirt and rustproofing.
   • Drill a 3/32” hole and secure the white wire with the provided eyelet and screw.

   Caution:

   • Verify the area behind before drilling to avoid damage or injury.

8. Connect the Power Wire:

   • From inside the vehicle, connect the black 12-gauge wire to the black wire from the T-One® black box using the yellow butt connector.
   • Route the black wire through the channel to the roof area, following existing wiring toward the driver's seat.
   • Conceal the wire behind plastic wire covers where possible.

9. Route the Wire to the Battery:

   • Continue routing the black wire behind the trim panel next to the driver's seat and along the vehicle floor.
   • Access the battery compartment beneath the driver-side floor.
   • Remove the screws holding the threshold and floor coverings, then expose the battery.

10. Connect to the Vehicle Battery:

    • Disconnect the negative (-) battery cable.
    • Attach the provided fuse holder to the positive (+) battery terminal using the provided ring terminal.
    • Connect the other end of the fuse holder to the black wire with the yellow butt connector.
    • Insert the 15-amp fuse into the fuse holder.

    Warning:

    • Follow all warnings and instructions for handling the vehicle battery.

11. Reconnect the Battery:

    • Reconnect the negative (-) battery cable.
    • Test the installation with a test light or trailer to ensure proper operation.

12. Secure and Reassemble:

    • Use cable ties to secure the remaining harness.
    • Replace all trim panels, covers, and components removed during installation, ensuring no wires are pinched or damaged.

13. Store the 4-Flat Connector:

    • Store the 4-flat connector in the vehicle's cargo area when not in use.

Specifications:

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

Safety Notes:

• Overloading circuits can cause fires. Do not exceed stated ratings or manufacturer specifications.
• Always wear safety glasses and follow safety precautions during installation.

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 and instruction sheet for additional details.
• Store these instructions for future reference.

Warranty Information:

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