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 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