Installation Instructions for 2020-Current Ford Explorer

Part Numbers:

• 76910

Installation Time:

• Approximately 40 minutes for professional installers.

Tools Required:

• Ratchet Torque Wrench
• Safety Glasses
• Sockets: 7mm, 10mm, 21mm
• 6” Socket Extension
• Exhaust Removal Pliers
• Marker
• Tape Measure
• Tin Snips
• Flat Head Screwdriver
• Drill Bit: 1/4”
• Plastic Rivet Gun
• Drill

Step-by-Step Instructions:

1. Install Receiver Housing:

   • Unlock the blue handle using the key provided.
   • Detach the housing from the receiver by pressing the blue handle and rotating clockwise until it clicks.
   • Attach the weather covers to the housing.
   • Secure the housing to the hitch using the M12 bolt, flat washer, and prevailing torque nut.
   • Tighten the fasteners to 92 Lb.-Ft. (125 N*M).

2. Place Warning Labels:

   • Store the warning card in the glove compartment.
   • Attach warning labels to the top of the receiver and the door jamb.

3. Remove Underbody Panel:

   • Use a 7mm socket and screwdriver to remove screws and push rivets holding the underbody panel in place.
   • Remove the panel between the mufflers. Trim for reuse if necessary.

4. Lower Exhaust:

   • Use a 10mm socket to remove bolts from the exhaust hanger on the frame rail.
   • Use exhaust removal pliers to remove rubber hangers near the rear differential.
   • Support the exhaust to prevent damage.

5. Remove Heat Shields:

   • Use a 10mm socket to remove nuts and a 7mm socket to remove screws attaching the heat shield.
   • Cut a 1.5” hole in the shield to accommodate the middle hitch fastener.

6. Remove M16 Bumper Bolts:

   • Use a 21mm socket to remove bumper bolts from the frame rail.

7. Trim Fascia:

   • Mark the center of the fascia and trim according to provided dimensions to allow hitch clearance.

8. Install Hitch:

   • Insert carriage bolts and spacers into the frame rail using pull wires.
   • Align hitch brackets with the frame rail weldnuts and guide pull wires through the hitch holes.
   • Loosely reinstall the M16 bumper bolts.
   • Remove pull wires and install conical washers (teeth side against hitch) and hex nuts.

9. Tighten Fasteners:

   • Torque all M16 fasteners to 146 Lb.-Ft. (198 N*M).
   • Torque all 1/2” fasteners to 75 Lb.-Ft. (102 N*M).

10. Reinstall Components:

    • Reattach the modified heat shields and underbody panel.
    • Reinstall exhaust and all removed fascia fasteners.

Hardware List:

• (2) Carriage Bolts: 1/2”-13 x 1.50” GR5
• (2) Spacer Blocks: 1/4” x 1” x 3”
• (2) Conical Washers: 1/2”
• (2) Hex Nuts: 1/2”-13 GR5
• (2) Pull Wires: 1/2”-13
• (4) Plastic Rivets

Safety Notes:

• Regularly inspect all fasteners to ensure they are secure.
• Plug all holes in the vehicle body if the hitch is removed to prevent water or exhaust fumes from entering.
• Replace any damaged hitch or ball.
• Always wear safety glasses during installation.
• Do not cut access or attachment holes with a torch.

Specifications:

• Hitch Type:
  • Weight Carrying: 3,500 lb. (1,589 kg) Max Gross Trailer Weight, 350 lb. (159 kg) Max Tongue Weight
  • Weight Distributing: Not Applicable
• This product complies with SAE J684 and New York V.E.S.C. Regulation V-5.

Installation Instructions for 2020-Current Vehicle Models

Part Numbers:

• 76910

Installation Time:

• Approximately 40 minutes for professional installers.

Tools Required:

• Ratchet Torque Wrench
• Safety Glasses
• Sockets: 7mm, 10mm, 21mm
• 6” Socket Extension
• Exhaust Removal Pliers
• Marker
• Tape Measure
• Tin Snips
• Flat Head Screwdriver
• Drill Bit: 1/4”
• Plastic Rivet Gun
• Drill

Step-by-Step Instructions:

1. Install Receiver Housing:

   • Unlock the blue handle using the key provided.
   • Detach the housing from the receiver by pressing the blue handle and rotating clockwise until it clicks.
   • Attach the weather covers to the housing.
   • Secure the housing to the hitch using the M12 bolt, flat washer, and prevailing torque nut.
   • Tighten the fasteners to 92 Lb.-Ft. (125 N*M).

2. Place Warning Labels:

   • Store the warning card in the glove compartment.
   • Attach warning labels to the top of the receiver and the door jamb.

3. Remove Underbody Panel:

   • Use a 7mm socket and screwdriver to remove screws and push rivets holding the underbody panel in place.
   • Remove the panel between the mufflers. Trim for reuse if necessary.

4. Lower Exhaust:

   • Use a 10mm socket to remove bolts from the exhaust hanger on the frame rail.
   • Use exhaust removal pliers to remove rubber hangers near the rear differential.
   • Support the exhaust to prevent damage.

5. Remove Heat Shields:

   • Use a 10mm socket to remove nuts and a 7mm socket to remove screws attaching the heat shield.
   • Cut a 1.5” hole in the shield to accommodate the middle hitch fastener.

6. Remove M16 Bumper Bolts:

   • Use a 21mm socket to remove bumper bolts from the frame rail.

7. Trim Fascia:

   • Mark the center of the fascia and trim according to provided dimensions to allow hitch clearance.

8. Install Hitch:

   • Insert carriage bolts and spacers into the frame rail using pull wires.
   • Align hitch brackets with the frame rail weldnuts and guide pull wires through the hitch holes.
   • Loosely reinstall the M16 bumper bolts.
   • Remove pull wires and install conical washers (teeth side against hitch) and hex nuts.

9. Tighten Fasteners:

   • Torque all M16 fasteners to 146 Lb.-Ft. (198 N*M).
   • Torque all 1/2” fasteners to 75 Lb.-Ft. (102 N*M).

10. Reinstall Components:

    • Reattach the modified heat shields and underbody panel.
    • Reinstall exhaust and all removed fascia fasteners.

Hardware List:

• (2) Carriage Bolts: 1/2”-13 x 1.50” GR5
• (2) Spacer Blocks: 1/4” x 1” x 3”
• (2) Conical Washers: 1/2”
• (2) Hex Nuts: 1/2”-13 GR5
• (2) Pull Wires: 1/2”-13
• (4) Plastic Rivets

Safety Notes:

• Regularly inspect all fasteners to ensure they are secure.
• Plug all holes in the vehicle body if the hitch is removed to prevent water or exhaust fumes from entering.
• Replace any damaged hitch or ball.
• Always wear safety glasses during installation.
• Do not cut access or attachment holes with a torch.

Specifications:

• Hitch Type:
  • Weight Carrying: 3,500 lb. (1,589 kg) Max Gross Trailer Weight, 350 lb. (159 kg) Max Tongue Weight
  • Weight Distributing: Not Applicable
• This product complies with SAE J684 and New York V.E.S.C. Regulation V-5.

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:

This product is covered by a warranty. For complete warranty information, please download the full installation PDF.

Installation Instructions for T-Connector Adapter for Ford Taurus, Lincoln MKS and Ford Explorer

Part Numbers:

• 118599

Tools Required:

• Trim Panel Remover
• 10mm Socket & Ratchet or 10mm Wrench
• 7mm Socket & Ratchet or 7mm Wrench
• Torx 25 Driver
• Drill (3/32” Drill Bit)
• 1/4” Socket
• Wire Crimpers
• Wire Cutters
• Phillips Head Screwdriver
• Test Probe

Step-by-Step Instructions:

Ford Taurus / Lincoln MKS:

1. Prepare the Rear Cargo Area:

   • Open the trunk and remove the threshold panel.
   • Partially remove the corner felt trunk liner on both sides to expose the vehicle’s taillight wiring harness.

2. Locate and Connect the Driver-Side Wiring:

   • Locate the driver’s side taillight wiring harness. Separate the connectors carefully to avoid breaking the locking tabs.
   • Attach the T-Connector with the yellow and brown wires to the driver’s side wiring connectors, ensuring all connections are secure with locking tabs in place.

3. Route the T-Connector Wiring:

   • Route the T-Connector containing the green wire below the threshold cover to the passenger side.
   • Repeat Step 2 for the passenger side using the T-Connector with the green and red wires.

4. Store the 4-Flat Connector:

   • Route the 4-flat connector through the driver’s side trim panel into the side storage compartment and store it there when not in use.

Ford Explorer:

1. Prepare the Rear Cargo Area:

   • Open the rear hatch and temporarily remove the rear threshold plate, privacy screen, storage covers, and floor covering.
   • Fold the rear seats forward.

2. Remove Interior Panels:

   • Partially remove the rear interior trim panels on both the driver’s and passenger’s sides.
   • Carefully remove fasteners and set aside panels to prevent damage.

3. Locate and Connect the Wiring Harness:

   • Locate the taillight wiring harness on both sides. Separate the connectors carefully and connect the T-Connector with the yellow wire on the driver’s side.
   • Route the T-Connector with the green wire to the passenger side and connect it to the passenger-side wiring connectors.

All Vehicles:

1. Mount the Black Box:

   • Locate a flat surface in an out-of-the-way location on the driver’s side.
   • Mount the T-Connector’s black converter box using the provided double-sided tape.

2. Ground the White Wire:

   • Locate a suitable grounding point on the driver’s side near the connectors.
   • Drill a 3/32” hole and secure the white wire with the provided eyelet and screw.

   Caution:

   • Verify what is behind any surface before drilling to prevent damage or injury. Do not drill into exposed surfaces.

3. Connect the Power Wire:

   • Locate the red 12-gauge power wire from the T-Connector box.
   • Attach the provided black 12-gauge wire using the yellow butt connector.
   • Route the black wire through a grommet or along the vehicle frame to the engine compartment and battery.

4. Connect to the Battery:

   • Disconnect the negative (-) battery cable.
   • Attach the fuse holder to the positive (+) battery cable using the provided ring terminal.
   • Connect the other end of the fuse holder to the black power wire and install the 10-amp fuse.

5. Reassemble the Vehicle:

   • Reinstall all removed trim panels, threshold covers, and floor coverings, ensuring no wires are pinched or cut.

6. Test the Installation:

   • Test the installation with a test light or trailer.
   • Reset the vehicle’s electrical system by temporarily removing the key from the ignition.

   Specifications:

   • Max. stop/turn light: 1 per side (2.1 amps)
   • Max. tail lights: (5.6 amps)

Safety Notes:

• Overloading circuits can cause fires. Do not exceed the towing manufacturer’s rating or unit specifications.
• Always follow the installation instructions and use safety glasses during the installation.

Manufacturer Notes:

• Refer to the vehicle owner’s manual for additional guidance.

Installation Instructions for T-Connector Adapter for Ford Taurus, Lincoln MKS, and Ford Explorer

Part Numbers:

• 118599

Tools Required:

• Trim Panel Remover
• 10mm Socket & Ratchet or 10mm Wrench
• 7mm Socket & Ratchet or 7mm Wrench
• Torx 25 Driver
• Drill (3/32” Drill Bit)
• 1/4” Socket
• Wire Crimpers
• Wire Cutters
• Phillips Head Screwdriver
• Test Probe

Step-by-Step Instructions:

Ford Taurus / Lincoln MKS:

1. Prepare the Rear Cargo Area:

   • Open the trunk and remove the threshold panel.
   • Partially remove the corner felt trunk liner on both sides to expose the vehicle’s taillight wiring harness.

2. Locate and Connect the Driver-Side Wiring:

   • Locate the driver’s side taillight wiring harness. Separate the connectors carefully to avoid breaking the locking tabs.
   • Attach the T-Connector with the yellow and brown wires to the driver’s side wiring connectors, ensuring all connections are secure with locking tabs in place.

3. Route the T-Connector Wiring:

   • Route the T-Connector containing the green wire below the threshold cover to the passenger side.
   • Repeat Step 2 for the passenger side using the T-Connector with the green and red wires.

4. Store the 4-Flat Connector:

   • Route the 4-flat connector through the driver’s side trim panel into the side storage compartment and store it there when not in use.

Ford Explorer:

1. Prepare the Rear Cargo Area:

   • Open the rear hatch and temporarily remove the rear threshold plate, privacy screen, storage covers, and floor covering.
   • Fold the rear seats forward.

2. Remove Interior Panels:

   • Partially remove the rear interior trim panels on both the driver’s and passenger’s sides.
   • Carefully remove fasteners and set aside panels to prevent damage.

3. Locate and Connect the Wiring Harness:

   • Locate the taillight wiring harness on both sides. Separate the connectors carefully and connect the T-Connector with the yellow wire on the driver’s side.
   • Route the T-Connector with the green wire to the passenger side and connect it to the passenger-side wiring connectors.

All Vehicles:

1. Mount the Black Box:

   • Locate a flat surface in an out-of-the-way location on the driver’s side.
   • Mount the T-Connector’s black converter box using the provided double-sided tape.

2. Ground the White Wire:

   • Locate a suitable grounding point on the driver’s side near the connectors.
   • Drill a 3/32” hole and secure the white wire with the provided eyelet and screw.

   Caution:

   • Verify what is behind any surface before drilling to prevent damage or injury. Do not drill into exposed surfaces.

3. Connect the Power Wire:

   • Locate the red 12-gauge power wire from the T-Connector box.
   • Attach the provided black 12-gauge wire using the yellow butt connector.
   • Route the black wire through a grommet or along the vehicle frame to the engine compartment and battery.

4. Connect to the Battery:

   • Disconnect the negative (-) battery cable.
   • Attach the fuse holder to the positive (+) battery cable using the provided ring terminal.
   • Connect the other end of the fuse holder to the black power wire and install the 10-amp fuse.

5. Reassemble the Vehicle:

   • Reinstall all removed trim panels, threshold covers, and floor coverings, ensuring no wires are pinched or cut.

6. Test the Installation:

   • Test the installation with a test light or trailer.
   • Reset the vehicle’s electrical system by temporarily removing the key from the ignition.

Specifications:

• Max. stop/turn light: 1 per side (2.1 amps)
• Max. tail lights: (5.6 amps)

Safety Notes:

• Overloading circuits can cause fires. Do not exceed the towing manufacturer’s rating or unit specifications.
• Always follow the installation instructions and use safety glasses during the 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.

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

Note: Store these instructions for future reference.