Installation Instructions for Ford Explorer 2 & 4 Door, Mazda Navajo, and Mercury Mountaineer

Part Numbers:

• 75096

Wiring Access Location:

• SUV1, SUV2

Tools Required:

• Wrenches: 3/4", 7/8"
• Drill Bits: 1/2"

Step-by-Step Instructions:

Attachment of Hitch-to-Frame Adapter Brackets:

1. Remove Tow Hooks (If Equipped):

   • Remove the tow hooks from the vehicle frame and return them to the owner for possible reinstallation if the hitch is removed.

2. Attach Adapter Brackets:

   • Secure the adapter brackets to the rearmost existing holes in the vertical surfaces of the vehicle frame. These holes are approximately 18" from the rear end of the frame.

3. Position Adapter Brackets:

   • Orient the brackets as shown in Figure 1. Align the brackets with the existing holes in the frame.

4. Install Bracket-to-Frame Fasteners:

   • Tighten the bracket-to-frame fasteners as shown in Figure 2.

Attachment of Hitch Assembly to Vehicle:

5. Measure and Adjust Brackets:

   • Ensure spacing between the "Long" hitch brackets is 33-7/8". Adjust if needed for proper alignment.

6. Raise Hitch into Position:

   • Align the hitch holes with the holes in the adapter bracket:
     • Use the lower holes in the adapter bracket for the passenger side.
     • Use the upper holes in the adapter bracket for the driver’s side.

7. Secure Hitch:

   • Install hitch-to-adapter bracket fasteners as shown in Figure 3.

8. Drill Holes for 1994 and Prior Models:

   • Using the hitch as a template, drill a 1/2" hole through the frame rail.

9. Install Fasteners for 1994 and Later Models:

   • Secure the hitch assembly using the provided fasteners.

10. Tighten All Fasteners:

    • Tighten all 1/2"-13 GR5 fasteners to 75 lb-ft (102 N*m).

Torque Specifications:

• 1/2"-13 GR5: 75 lb-ft (102 N*m)

Hardware List:

• (6) 1/2"-13 x 1-3/4" GR5 Carriage Bolts
• (6) Lock Washers
• (6) Hex Nuts
• (6) Blocks (1/4" x 1-1/2" x 2")

Safety Notes:

• Regularly inspect the hitch to ensure all fasteners and the ball are securely tightened.
• Replace any damaged hitch or ball immediately.
• If the hitch is removed, plug any holes in the frame or body panels to prevent water or exhaust fumes from entering.
• Always wear safety glasses and observe proper safety precautions when working beneath the vehicle.
• 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: 7,500 lb (3,402 kg)
  • Max Tongue Weight: 750 lb (340 kg)

Additional Notes:

• This product complies with SAE J684 and V.E.S.C. Regulation V-5 safety standards.
• Ensure all fasteners are properly torqued before towing.

Installation Instructions for T-Connector Trailer Wiring Harness

Product Information:

• Part Number: N118345
• Application: Compatible vehicles

Tools Required:

• Drill with 3/32” drill bit
• Philips Head Screwdriver

Step-by-Step Instructions:

1. Remove the Vehicle Taillights:

   • Open the vehicle’s rear tailgate.
   • Remove the two screws on each taillight assembly.
   • Carefully pull the taillight assemblies away to avoid damage.

2. Prepare the T-Connector Harness:

   • Stretch the T-connector wiring harness across the rear bumper, ensuring the connector with the green wire is on the passenger (right) side.

3. Install the Driver-Side T-Connector:

   • On the driver’s side, route the black box and connectors with the yellow and red wires through the access hole below the vehicle and up into the taillight opening.
   • Disconnect the top gray taillight socket and plug the T-Connector with the yellow wire between the disconnected halves.
   • Disconnect the center black taillight socket and plug the T-Connector with the red wire between the disconnected halves.
   • Ensure all connectors are fully seated, and the locking tabs are secure.

4. Ground the White Wire:

   • Drill a 3/32” hole into the metal cross brace inside the taillight opening.
   • Attach the white wire using the provided eyelet and screw.

5. Install the Passenger-Side T-Connector:

   • Route the T-Connector with the green wire across the vehicle and up into the passenger-side taillight opening.
   • Disconnect the top gray taillight socket and plug the T-Connector with the green wire between the disconnected halves.
   • Ensure all connectors are locked securely.

6. Connect the Power Wire:

   • Disconnect the vehicle’s negative (-) battery cable.
   • Remove the fuse from the supplied fuse holder.
   • Use the provided ring terminal to connect one end of the fuse holder to the vehicle’s positive (+) battery terminal.
   • Use the yellow butt connector to attach the other end of the fuse holder to the included black 12-gauge wire.

7. Route the Power Wire:

   • Route the black 12-gauge power wire from the front of the vehicle along the driver-side frame rail toward the rear of the vehicle.
   • Avoid routing the wire near hot pipes, heat shields, fuel tanks, or sharp edges.
   • Route the wire up through the same access hole used for the driver-side connectors.

8. Connect the Power Wire to the T-Connector:

   • Attach the black 12-gauge wire to the red wire on the T-Connector’s black box using the supplied yellow butt connector.

9. Install the Fuse and Test the System:

   • Reconnect the vehicle’s negative battery cable.
   • Install the provided 10-amp fuse into the fuse holder.
   • Use a test light or connect a trailer to verify proper functionality of:
     • Running Lights
     • Left Turn Signal
     • Right Turn Signal
     • Brake Lights

10. Mount the Black Module Box:

    • Clean a flat area near the black box using rubbing alcohol and water.
    • Mount the black module box using the provided foam tape.

11. Secure the Wiring Harness:

    • Use the provided cable ties to secure all loose wiring under the vehicle.
    • Ensure the wiring is routed safely away from sharp edges, moving parts, and hot components.

12. Route the 4-Flat Connector:

    • Route the 4-flat connector through the taillight access hole and secure it under the vehicle.
    • Optional: Expose the vehicle’s jack storage compartment by removing the access panel. Slit the rubber grommet between the taillight opening and the jack storage compartment. Push the 4-flat connector through for storage.

13. Reassemble the Vehicle Components:

    • Reinstall the access panels and the taillight assemblies in their original positions.

Specifications:

• Current Rating: 4 amps per circuit

Safety Notes:

• Verify the installation by testing all trailer lighting functions before towing.
• Avoid overloading the circuits beyond the specified amperage limits.
• Routinely inspect the wiring system for signs of wear, corrosion, or damage.

Warnings:

• Do not route wires near hot exhaust components, sharp edges, or areas that may pinch the wiring.
• Follow all safety precautions when working near the vehicle’s battery.

Technical Support:
For further assistance, contact the manufacturer’s technical support team.

Note: Store the 4-flat connector securely when not in use to prevent damage.