Installation Instructions for Ford F-150 and Lincoln Mark LT

Part Numbers:

• 37090
• 41549
• 82595

Wiring Access Location:

• PU3

Tools Required:

• Drill with 7/16" Drill Bit
• Wrenches: 3/4"
• Fishwire (provided)

Step-by-Step Instructions:

1. Prepare Vehicle:

   • Lower the spare tire to ease installation.
   • For vehicles with a vibration dampener assembly mounted on the driver’s side frame rail:
     • Remove and retain the dampener and its fasteners for reinstallation later (refer to Figure 2).
     • Note: Vibration dampeners cannot be reinstalled on Flareside models.

2. Position Hitch:

   • Raise the hitch into position, aligning the holes in the hitch side brackets with the holes in the vehicle frame.

3. Install Rear Fasteners:

   • Insert a 1/2"-13 carriage bolt and 1/4" x 3" block through the end of the frame and into the rearmost slot on each side.
   • Secure with 1/2" lock washers and nuts. Finger-tighten only at this stage.

4. Fishwire Forward Bolts:

   • Fishwire two (2) 1/2"-13 carriage bolts and 1/4" x 3" blocks through the forward square hole in the side of the frame rail and into the aligned holes in the hitch side bracket on both sides.
   • Secure with 1/2" lock washers and nuts.

   Notes:

   • Ensure blocks do not overlap inside the frame before tightening.
   • On vehicles with a vibration dampener, reinstall the dampener (see Figure 2) before tightening fasteners.

5. Tighten Fasteners:

   • Use a torque wrench to tighten all 1/2"-13 GR5 fasteners to 75 lb-ft.

6. Raise Spare Tire:

   • Reinstall the spare tire.

Reinstalling Vibration Dampener (if applicable):

1. Attach the dampener bracket to the dampener using two (2) existing M10 fasteners. Tighten to 38 lb-ft.

2. Raise the dampener with the bracket attached and secure it with 1/2" fasteners at the rearmost driver’s side attachment point.

3. Drill a 7/16" hole through the spring shackle bracket and the adjoining face of the dampener bracket. Secure with the existing M10 fastener.

   Torque Specifications:

   • M10 fasteners: 38 lb-ft
   • 1/2"-13 GR5 fasteners: 75 lb-ft

Hardware List:

• (6) Carriage Bolts, 1/2"-13
• (6) Blocks, 1/4" x 3"
• (6) Lock Washers, 1/2"
• (6) Hex Nuts, 1/2"-13

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 other body panels to prevent water or exhaust fumes from entering.
• Replace any damaged hitch or ball immediately.
• Observe safety precautions when working beneath a vehicle and wear eye protection.
• Do not cut access or attachment holes with a torch.

Specifications:

• Weight Carrying (Ball Mount):
  • Max Gross Trailer Weight: 6,000 lb
  • Max Tongue Weight: 600 lb
• Weight Distributing:
  • Max Gross Trailer Weight: 10,000 lb
  • Max Tongue Weight: 1,000 lb

Additional Notes:

• This product complies with V.E.S.C. Regulation V-5 and SAE J684 safety standards.

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