Installation Instructions for Chrysler Town & Country, Dodge Grand Caravan, VW Routan, and Ram C/V Tradesman

Part Numbers:

• 75579
• 87451
• 44586

Tools Required:

• Wrenches: 13mm, 15mm, 18mm
• Drill Bits: None

Wiring Access Location:

• SUV1, SUV2

Step-by-Step Instructions:

1. Lower Exhaust:

   • Remove the bolt attaching the rearmost hanger bracket to the passenger-side frame rail.
   • Retain the bolt for reinstallation.

2. Install Plastic Loom (if applicable):

   • Snap the plastic loom in place over the air conditioning line near the bolt (if present) to protect it. See Figure 2.

3. Remove Existing Bolts:

   • On the driver's side, remove three (3) bolts from the frame rail.
   • On the passenger's side, remove two (2) bolts.
   • Retain all bolts for hitch installation.

4. Remove Plastic Rivet (Driver's Side):

   • Remove the plastic rivet securing the plastic mud flap to the driver's side frame rail.
   • After hitch installation, trim the plastic corner of the mud flap if necessary.
   • Do not reinstall the plastic rivet.

5. Raise the Hitch:

   • Position the hitch and secure it with the bolts removed in Step 3.
   • Hand-tighten the fasteners.

6. Align Hitch:

   • Push the hitch toward the driver's side so the passenger-side bracket contacts the trunk pan.

7. Tighten Fasteners:

   • Torque all M10 CL10.9 fasteners to 53 lb-ft (72 N·m).
   • Torque all M12 CL10.9 fasteners to 92 lb-ft (125 N·m).

8. Reinstall Exhaust:

   • Raise the exhaust back into position and reinstall the bolt removed in Step 1.

   Note: Rotating the exhaust hanger bracket before tightening will provide additional clearance between the hitch bracket and exhaust.

Hardware List:

• (5) Existing M10 Bolts (from vehicle frame)
• (2) Existing M12 Bolts (from vehicle frame)

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 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 Distributing: Max Trailer Weight 5,000 lbs (2,270 kg), Max Tongue Weight 500 lbs (227 kg).
  • Weight Carrying (Ball Mount): Max Trailer Weight 4,000 lbs (1,816 kg), Max Tongue Weight 400 lbs (182 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 Chrysler Town & Country

Part Numbers:

• 118534

Tools Required:

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

Step-by-Step Instructions:

1. Remove the Taillight Assemblies:

   • Open the rear tailgate to access the screws securing the taillights.
   • Remove the T-30 Torx screws and carefully pry the taillight housings rearward, avoiding damage to the alignment tabs.

2. Disconnect the Wiring Harness:

   • Behind each taillight housing, locate the connection points matching the T-Connector adapter ends.
   • Separate the vehicle’s wiring connectors, being careful not to damage the locking tabs.
   • Insert the T-Connector end with the yellow wire on the driver’s side between the vehicle wiring connectors and lock into place.

3. Route the Harness:

   • On the driver’s side, route the T-Connector harness containing the green wire and the 4-flat connector down the opening behind the taillight.
   • Route the 4-flat connector to the center of the vehicle and the green wire underneath to the passenger side.

   Warning:

   • Avoid routing near hot pipes, heat shields, the fuel tank, or areas where the wire could be pinched or broken.

4. Install the Passenger-Side T-Connector:

   • Repeat Step 2 on the passenger side using the T-Connector with the green wire.

5. Ground the White Wire:

   • Locate a suitable grounding point near the connectors.
   • Drill a 3/32” hole and secure the white wire using the provided eyelet and screw.

   Caution:

   • Verify what is behind the surface before drilling to avoid vehicle or personal damage.

6. Connect the Power Wire:

   • On the driver’s side, locate the black 12-gauge power wire from the T-Connector box and attach it to the supplied black wire.
   • Route the black wire through the taillight socket, behind the bumper, and along the frame to the engine compartment.

   Warning:

   • Avoid routing near hot pipes, heat shields, or areas where the wire could be pinched or damaged.

7. Connect to the Vehicle Battery:

   • Disconnect the negative (-) battery terminal.
   • Remove the fuse from the yellow fuse holder.
   • Attach the ring terminal to the positive (+) battery cable and secure it.
   • Connect the other end of the fuse holder to the black 12-gauge wire using the provided yellow butt connector.

8. Reconnect the Battery:

   • Reconnect the negative (-) battery cable.
   • Insert the 10-amp fuse into the fuse holder.

9. Mount the Black Box:

   • Mount the T-Connector’s black box using the provided double-sided tape.
   • Ensure the epoxy side of the module faces downward to prevent water buildup.
   • Secure the remaining harness with cable ties.

10. Test the Installation:

    • Test the T-Connector with a test light or trailer. Ensure all connections are complete for proper functionality.

11. Reinstall the Taillights:

    • Reinstall the taillight assemblies and any items removed during installation, ensuring no wires are pinched or damaged.

    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 towing manufacturer’s rating or the specified maximum ratings.
• Always wear safety glasses and follow all safety precautions.

Manufacturer Notes:

• Refer to the vehicle owner’s manual and instruction sheet for additional details.