Installation Instructions for Chevrolet/GMC Pickup, Dodge Pickup, Dodge Ramcharger, Ford Pickup (1980 and Later), Ford Bronco, Ford F350 Super Duty Cab & Chassis, International Pickup, and Plymouth Trailduster

Part Numbers:

• 41504
• 37081
• 44143
• 87480

Wiring Access Location:

• PU1, PU2

Tools Required:

• Wrenches: 3/4", 13/16", 7/8"
• Drill with 1/2" Drill Bit

Installation Time:

• Estimated: Not specified

Step-by-Step Instructions:

1. Remove Spare Tire:

   • Remove the spare tire from the vehicle.
   • Note: To retain under-box tire storage, the spare tire carrier may need to be relocated or modified.
   • For Ford models with 16" spare tires, adjust the spare tire cradle to maintain proper storage after hitch installation.

2. Measure Frame Width:

   • For 34" frames: Position side brackets with mounting flanges pointing inboard.
   • For 38" frames: Position side brackets with mounting flanges pointing outboard.

3. Position Side Brackets:

   • Lift the side bracket into position, ensuring the rearmost mounting tab aligns with the end of the vehicle frame.
   • Clamp the bracket to the frame.

4. Drill Holes:

   • Using the slotted holes in the bracket as a guide, drill six (6) 1/2" diameter holes in the frame.
   • Note: Existing holes in the frame may be used if available.

5. Install Side Bracket Fasteners:

   • Place blocks inside the frame and install the provided hardware as shown in the instructions.
   • Do not tighten the fasteners at this stage.

6. Special Installation for Ford Pickups (1980 and Later):

   • These models require the 1685 Fastener Kit (sold separately).

7. Repeat for Opposite Side:

   • Repeat Steps 3, 4, and 5 on the opposite side of the vehicle.

8. Install Crosstube Assembly:

   • Position the crosstube between the side brackets.
   • Secure it using the provided bolts, flat washers, and flanged locknuts.
   • Torque to 95 lb-ft (129 N*m).

9. Tighten All Side Bracket Fasteners:

   • Torque the side bracket fasteners to 75 lb-ft (102 N*m).

Torque Specifications:

• Crosstube Fasteners: 95 lb-ft (129 N*m)
• Side Bracket Fasteners: 75 lb-ft (102 N*m)

Hardware List:

• (6) Carriage Bolts, 1/2"-13 x 1.75"
• (6) Carriage Bolts, 1/2"-13 x 2.25" (*)
• (6) Hex Bolts, 1/2"-20 x 1.50"
• (6) Conical Washers, 1/2"
• (6) Flat Washers
• (6) Flange Locknuts, 1/2"-20
• (6) Hex Nuts, 1/2"-13
• (2) Blocks, 1/4" x 1-1/2" x 2" (*)
• (2) Bevel Washers (*)
• (2) Blocks, 5/8" x 1" x 2" (*)

(* Included in the 1685 Fastener Kit, sold separately for Ford models)

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:

• Weight Carrying (Ball Mount):
  • Max Gross Trailer Weight: 5,000 lb (2,270 kg)
  • Max Tongue Weight: 500 lb (227 kg)
• Weight Distributing:
  • Max Gross Trailer Weight: 10,000 lb (4,540 kg)
  • Max Tongue Weight: 1,000 lb (454 kg)

Additional Notes:

• For vehicles equipped with "Deep Drop" step bumpers, 1981 and later Chevrolet/GMC models require the removal of support brackets from the frame.
• This product complies with V.E.S.C. Regulation V-5 and SAE J684 safety standards.

Installation Instructions for T-Connector Adapter

Part Numbers:

• 118329

Wiring Access Location:

• Near the rear frame of the vehicle.

Tools Required:

• Tie straps (provided in the kit).

Step-by-Step Instructions:

1. Locate the vehicle’s taillight wiring harness near the rear of the frame.

   • The harness will have connection points on both sides with connectors matching the ends of the T-Connector adapter.

2. Separate the harness connectors on the left (driver’s) side.

   • Note: Be careful not to break the locking tabs.
   • Ensure that the mating surfaces of the connectors are free of dirt and clean them if necessary.

3. Insert the T-Connector adapter with the yellow wire between the harness connectors and lock into place.

   • Verify that the connectors are fully inserted with locking tabs secure.

4. Repeat steps 2 and 3 on the right (passenger’s) side, using the T-Connector with the green wire.

5. Route the T-Connector harness to the center of the vehicle.

   • Secure the wire to the vehicle crossmember using the provided tie straps.

6. Test the installation with a test light or trailer.

   • Specifications:
     • This unit is rated for 7.5 amps per circuit.

Hardware List:

• T-Connector adapter.
• Tie straps.

Safety Notes:

• Handle all connectors with care to avoid damage.
• Ensure all connections are clean and securely fastened.
• Test the installation after completing all steps to verify functionality.

Manufacturer Notes:

• Follow all warnings and instructions provided with the product.
• Use a test light or trailer to confirm proper installation.