Installation Instructions for Chrysler Town & Country, Dodge Caravan, and Plymouth Voyager

Part Numbers:

• 75119
• 44006
• 78214 UH

Wiring Access Location:

• SUV1 & SUV2

Tools Required:

• Wrenches: 15mm, 17mm, 18mm, 19mm, 7/8"
• Drill Bits: 7/16"

Step-by-Step Instructions:

For Normal Installation (Without Rear Stabilizer Bar):

1. Remove Front Bumper Bolts:

   • Remove the front bumper bolts on both sides.

2. Install M12 x 1.75 Stud:

   • Insert the stud into position until it seats to the frame where the bumper bolt was removed.
   • Final tightening will occur when the nuts are tightened.

3. Remove Rear Bumper Bolts:

   • Remove the rear bumper bolts and place the hitch into position as shown.

4. Drill Holes:

   • Using the hitch as a template, drill a 7/16" hole in each frame rail for the forward attachment. Refer to Figure 1 for the hole location.

5. Fishwire Bolts:

   • Fishwire the 7/16" bolts and blocks through the oval hole on the side brackets.

6. Secure Fasteners:

   • Tighten the bolts and nuts to the specified torque values:
     • 7/16" GR5 Fasteners: 50 lb-ft (68 N·m)
     • M10 Fasteners: 42 lb-ft (57 N·m)
     • M12 Fasteners: 75 lb-ft (102 N·m)

For Short Wheel Base with Rear Stabilizer Bar:

1. Follow the same procedure as above, but refer to Figure 2 for adjustments related to the stabilizer bar bracket installation.

Torque Specifications:

• 7/16"-14 GR5: 50 lb-ft (68 N·m)
• M10: 42 lb-ft (57 N·m)
• M12: 75 lb-ft (102 N·m)

Hardware List:

• (2) M12 x 1.75 Studs
• (2) 1/4" x 1-1/2" x 2" Blocks
• (2) M10 x 1.5 x 35mm CL10.9 Bolts
• (2) Conical Toothed Washers (M10)
• (2) Conical Toothed Washers (M12)
• (2) 7/16"-14 x 1-3/4" GR5 Carriage Bolts
• (2) 1/4" x 1" x 3" Blocks
• (2) 3/16" x 1-1/2" x 2" Blocks
• (2) Lock Washers
• (2) Hex Nuts

Safety Notes:

• Inspect the hitch frequently to ensure all fasteners and the ball are securely tightened.
• Replace any damaged hitch or ball immediately.
• If the hitch is removed, plug all holes to prevent water or exhaust fumes from entering.
• Wear eye protection and follow 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: 3,500 lb (1,588 kg)
  • Max Tongue Weight: 350 lb (159 kg)
• Weight Distributing:
  • Max Gross Trailer Weight: 5,000 lb (2,268 kg)
  • Max Tongue Weight: 500 lb (227 kg)

Compliance:

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

Installation Instructions for T-Connector Adapter

Part Numbers:

• 118334

Wiring Access Location:

• Tail light wiring harness near the rear of the vehicle.

Tools Required:

• Utility knife.
• Drill with a 3/32" drill bit.
• Screw or cable ties (provided in the kit).

Step-by-Step Instructions:

1. Remove both of the vehicle’s rear tail lamp housings.
   • Slide the red locking tab on the harness connector to the unlocked position.
   • Disconnect the wire harness from both tail lamp sockets.

Vehicle-Specific Instructions:

2A. Minivans:

• Pull the vehicle’s wiring harness and rubber grommet slightly out on the driver’s side.
• Plug the T-Connector end with the yellow wire between the mating plug on the tail light socket and the vehicle wiring harness.
• Lock the connectors with the red locking tab.
• Repeat this procedure for the passenger’s side using the T-Connector end with the green wire.

2B. Durango:

• Temporarily remove the black air baffle below the rubber grommet on the driver’s side.
• Push the vehicle’s wiring and rubber grommet into the area behind the baffle.
• Place the T-Connector harness behind the air baffle and plug the T-Connector end with the yellow wire into the mating plug on the vehicle’s wiring harness.
• Lock the connectors with the red locking tabs.

3. With the vehicle wiring and grommets exposed:
   • Slit the grommet on the driver’s side using a utility knife.
   • Unwrap or cut the tape around the grommet tabs and pull the wiring slightly out on the passenger’s side.
   • Repeat this step on the passenger’s side.

4A. Minivans:

• Open the vehicle’s jack storage compartment on the driver’s side.
• Push the T-Connector 4-flat connector inside through the tail light wiring hole and into the storage compartment.

4B. Durango:

• Route the T-Connector end with the green wire and the 4-flat connector through the grommet hole from inside to outside.
• Route the green wire to the passenger’s side and secure the 4-flat underneath the bumper.

5. Reposition the rubber grommets on both sides over the T-Connector wiring.

   • Push all existing wires back into the grommet holes and reseat the grommets.

6. Secure the black converter box and trailer wiring using double-sided tape, electrical tape, or cable ties.

   • Place the converter box inside the jack storage compartment or behind the air baffle.

7. Replace all removed trim panels, air baffles, and tail lamp housings.

   • Position the wire harness between the housing and the vehicle body.
   • Secure the T-Connector harness under the bumper using the provided cable ties.

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

   • Specifications:
     • Max. stop/turn light: 1 per side (2.1 amps).
     • Max. tail light: (4.2 amps).

Hardware List:

• T-Connector adapter.
• Black box.
• Cable ties.
• Double-sided tape.

Safety Notes:

• Handle all connectors with care to avoid damage.
• Ensure all connections are clean and securely fastened.
• Do not drill into exposed surfaces.
• 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.
• Overloading circuits can cause fires. Adhere to specified ratings.