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 Trailer Light Wiring Kit

Part Number:

• 20252

Tools Required:

• Hot Air Gun or Appropriate Heat Source
• Wire Crimpers
• Drill (3/32” Drill Bit)
• Phillips Head Screwdriver
• Circuit Tester

Step-by-Step Instructions:

Step 1: Locate the Taillight Wiring Harness

1. Access the vehicle's taillight wiring harness.
2. Using the provided instructions, identify the appropriate wires for connection:
   • Green Wire: Right Turn & Stop
   • Yellow Wire: Left Turn & Stop
   • Brown Wire: Taillights
   • White Wire: Ground

Step 2: Make the Electrical Connections

1. Match the color-coded wires from the wiring kit to the corresponding vehicle wires.

   • Use a circuit tester to verify each wire's function before connecting.
   • CAUTION: Test one wire at a time to prevent damage to electronic components.

2. Connect the wires using the provided insulated butt connectors:

   • Strip the ends of each wire and seat them properly in the connector.
   • Use a crimping tool designed for insulated splices to secure the connections.

3. Heat the connectors:

   • Apply heat directly to the center of each splice using a hot air gun.
   • Work from the center outward until the tubing recovers and adhesive flows.
   • Allow the connections to cool before inspecting for integrity.

Step 3: Ground the System

1. Locate a grounding point near the wiring harness, such as the vehicle frame or cross member.
   • Do not drill into the vehicle floor or bed.
2. Clean the area to remove dirt, rust, or undercoating.
3. Drill a 3/32" hole at the grounding point and secure the white wire using the provided eyelet and screw.

Step 4: Verify the Installation

1. Test all connections using a circuit tester or trailer:
   • Verify the functionality of taillights, turn signals, and brake lights.
   • Ensure all connections are complete and secure.
2. If issues are identified, double-check the wiring and connections for errors.

Step 5: Store the 4-Flat Connector

• Store the 4-flat connector in the rear cargo area when not in use to protect it from damage and environmental exposure.

Warnings and Notes:

• WARNING: Overloading a circuit can cause fires. Do not exceed the following limits:
  • Stop/Turn Lights: 7.5 amps (1 per side)
  • Tail Lights: 7.5 amps
• WARNING: Always verify what is behind any surface before drilling to avoid vehicle damage or injury.
• NOTE: Trailer lighting that requires more than 7.5 amps per circuit must use a Trailer Light Power Converter.
• NOTE: If your trailer requires a plug other than the 4-flat, consult your dealer for optional 6-way or 7-way adapters.

Maintenance:

• Inspect the wiring harness periodically for damage, corrosion, or loose connections.
• Reapply heat to connectors if the adhesive seal weakens.

Specifications:

• Maximum Load:
  • Stop/Turn Lights: 7.5 amps (1 per side)
  • Tail Lights: 7.5 amps
• Recommended Grounding Hole Size: 3/32 inches

Installation Instructions for Trailer Light Wiring Kit

Part Number:

• 20252

Tools Required:

• Hot Air Gun or Appropriate Heat Source
• Wire Crimpers
• Drill (3/32” Drill Bit)
• Phillips Head Screwdriver
• Circuit Tester

Step-by-Step Instructions:

Step 1: Locate the Taillight Wiring Harness

1. Access the vehicle's taillight wiring harness.
2. Using the provided instructions, identify the appropriate wires for connection:
   • Green Wire: Right Turn & Stop
   • Yellow Wire: Left Turn & Stop
   • Brown Wire: Taillights
   • White Wire: Ground

Step 2: Make the Electrical Connections

1. Match the color-coded wires from the wiring kit to the corresponding vehicle wires.

   • Use a circuit tester to verify each wire's function before connecting.
   • CAUTION: Test one wire at a time to prevent damage to electronic components.

2. Connect the wires using the provided insulated butt connectors:

   • Strip the ends of each wire and seat them properly in the connector.
   • Use a crimping tool designed for insulated splices to secure the connections.

3. Heat the connectors:

   • Apply heat directly to the center of each splice using a hot air gun.
   • Work from the center outward until the tubing recovers and adhesive flows.
   • Allow the connections to cool before inspecting for integrity.

Step 3: Ground the System

1. Locate a grounding point near the wiring harness, such as the vehicle frame or cross member.
   • Do not drill into the vehicle floor or bed.
2. Clean the area to remove dirt, rust, or undercoating.
3. Drill a 3/32" hole at the grounding point and secure the white wire using the provided eyelet and screw.

Step 4: Verify the Installation

1. Test all connections using a circuit tester or trailer:
   • Verify the functionality of taillights, turn signals, and brake lights.
   • Ensure all connections are complete and secure.
2. If issues are identified, double-check the wiring and connections for errors.

Step 5: Store the 4-Flat Connector

• Store the 4-flat connector in the rear cargo area when not in use to protect it from damage and environmental exposure.

Warnings and Notes:

• WARNING: Overloading a circuit can cause fires. Do not exceed the following limits:
  • Stop/Turn Lights: 7.5 amps (1 per side)
  • Tail Lights: 7.5 amps
• WARNING: Always verify what is behind any surface before drilling to avoid vehicle damage or injury.
• NOTE: Trailer lighting that requires more than 7.5 amps per circuit must use a Trailer Light Power Converter.
• NOTE: If your trailer requires a plug other than the 4-flat, consult your dealer for optional 6-way or 7-way adapters.

Maintenance:

• Inspect the wiring harness periodically for damage, corrosion, or loose connections.
• Reapply heat to connectors if the adhesive seal weakens.

Specifications:

• Maximum Load:
  • Stop/Turn Lights: 7.5 amps (1 per side)
  • Tail Lights: 7.5 amps
• Recommended Grounding Hole Size: 3/32 inches

Warranty Information:

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.

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.

Revision:

20252 Rev. A 2-6-07