Installation Instructions for Toyota RAV4

Part Numbers:

• 75235
• 87697
• 44785

Applications:

• 2006-Current Toyota RAV4 (*Visit the manufacturer's website for the most up-to-date application years and trim levels.)

Tools Required:

• Ratchet
• Torque Wrench
• Safety Glasses
• Sockets: 10mm, 12mm, 17mm, 19mm
• Flat Head Screwdriver
• 6" Socket Extension
• Pliers

Installation Time:

• Approximately 20 minutes (for professional installers)

Step-by-Step Instructions:

1. Driver Side Appearance Panel Removal:

   • Use a flat head screwdriver and a 10mm socket to remove (2) plastic rivets and (1) flange nut from the driver side bottom appearance panel (see Figure 2).
   • Return the panel to the vehicle owner.

2. Tie-Down Bracket Removal:

   • Use a 17mm socket to remove (2) bolts securing the tie-down bracket (see Figure 3).

3. Lower the Exhaust:

   • Use pliers to remove (1) rubber isolator from the exhaust rod on the passenger side.

4. Exhaust Rod Removal:

   • Use a 12mm socket to remove (2) bolts securing the exhaust rod near the trunk pan (see Figure 4).
   • Return the bolts and rod to the vehicle owner.

5. Hitch Installation:

   • Raise the hitch into position over the existing weldnuts in the frame.
   • Loosely install (5) M12 bolts with conical washers into the weldnuts.
   • Note: Sandwich the hitch bracket between the frame rail and the tie-down bracket on the driver side (see Figure 1).

6. Tighten Fasteners:

   • Use a torque wrench to tighten all fasteners to 76 lb-ft (103 N·m).

7. Reinstall Exhaust Rod:

   • Attach the exhaust rod back to the rubber isolator.

8. Check Installation:

   • Verify that all fasteners are properly tightened.
   • Inspect for any interference with the hitch or surrounding components.

Hardware List:

• (5) M12 x 1.25 x 40mm CL10.9 Bolts
• (5) 1/2" Conical Washers

Safety Notes:

• Check the hitch frequently 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.
• Follow all 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: Max Trailer Weight 4,500 lbs (2,043 kg), Max Tongue Weight 675 lbs (306 kg).
  • Weight Distributing: Max Trailer Weight 4,500 lbs (2,043 kg), Max Tongue Weight 675 lbs (306 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.

Installation Instructions for T-Connector Adapter for Toyota RAV-4 and Toyota Avalon

Part Numbers:

• 118578

Tools Required:

• Trim Panel Remover
• 10mm & 14mm Socket & Ratchet or Wrench
• Drill (3/32” Drill Bit)
• 1/4” Socket
• Wire Crimpers
• Wire Cutters
• Phillips Head Screwdriver
• Test Probe

Step-by-Step Instructions:

1. Prepare the Vehicle:

   • For Toyota RAV-4:
     • Open the rear hatch and temporarily remove the rear threshold plate, privacy screen, storage covers, and floor covering.
     • Open the rear door and fold the rear seat forward.
   • For Toyota Avalon:
     • Open the trunk and temporarily remove the rear threshold plate.
     • Partially remove the felt trunk liner behind the taillights.

2. Remove Interior Trim Panels:

   • Partially remove the rear interior trim panels on both driver and passenger sides to expose the taillight wiring.
   • Remove the fasteners carefully to avoid damage to the clips or panels.

3. Locate the Taillight Wiring Harness:

   • On both driver and passenger sides, locate the vehicle's taillight wiring harness.
   • Disconnect the harness carefully, ensuring not to damage the locking tabs.
   • Clean the connectors to ensure proper contact.

4. Connect the Driver-Side T-Connector:

   • Insert the T-Connector end with the yellow wire between the driver-side taillight wiring connectors.
   • Ensure the connectors are fully inserted and secured with locking tabs.

5. Route the Passenger-Side T-Connector:

   • Route the T-Connector with the green wire along the rear threshold to the passenger side.
   • Repeat Step 4 to connect the green wire to the passenger-side taillight connectors.

6. Mount the T-Connector Black Box:

   • Locate a flat surface near the driver-side taillight wiring.
   • Mount the black converter box using the provided double-sided tape.

7. Ground the White Wire:

   • Locate a suitable grounding point near the connector or drill a 3/32” hole.
   • Secure the white wire with the provided eyelet and screw.

   Caution:

   • Avoid drilling into the vehicle floor or any exposed surfaces. Verify what lies beneath the surface before drilling.

8. Connect the Power Wire:

   • Locate the black 12-gauge power wire from the T-Connector box.
   • Attach the provided black wire using the supplied yellow butt connector.

9. Route the Power Wire:

   • Route the black power wire through a grommet and along the exterior frame or existing wiring to the vehicle's engine compartment.

   Warning:

   • Avoid routing near hot pipes, heat shields, fuel tanks, or areas that may damage the wire.

10. Connect to the Vehicle Battery:

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

11. Reconnect the Battery:

    • Reconnect the negative (-) battery cable and test the system with a test light or trailer.

    Warning:

    • All connections must be complete for the T-Connector to function properly.

12. Secure the Wiring:

    • Secure the remaining harness with the provided cable ties, avoiding areas that could pinch, cut, or melt the wires.

13. Reassemble the Vehicle:

    • Replace all removed components, including trim panels, threshold, cargo trays, and taillights.

14. Store the 4-Flat Connector:

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

Specifications:

• Max. stop/turn light: 2 per side (4.2 amps)
• Max. tail lights: 7.5 amps

Safety Notes:

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

Manufacturer Notes:

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