Installation Instructions for Dodge Van

Part Numbers:

• 75140
• 87492

Wiring Access Location:

• SUV5

Tools Required:

• Hacksaw
• Pliers
• Wrenches: 5/8", 11/16", 3/4", 7/8"

Specifications:

• Max Gross Trailer Weight:
  • Weight Distributing: 10,000 lb. (4,536 kg)
  • Weight Carrying: 5,000 lb. (2,268 kg)
• Max Tongue Weight:
  • Weight Distributing: 1,000 lb. (454 kg)
  • Weight Carrying: 500 lb. (227 kg)
• Note: Do not exceed the towing vehicle manufacturer’s rating.

Step-by-Step Instructions:

1. Remove Bumper Bolts:

   • Remove two (2) inboard bolts on the bumper mounting bracket (each side). Return the bolts to the vehicle owner.

2. Cut Metal Tabs:

   • Use a hacksaw to cut the sheet metal tabs on both sides as indicated. Bend the tabs out of the way to provide clearance for the hitch side brackets.

3. Fishwire Fasteners:

   • Use the fishwire method to guide carriage bolts and spacer blocks through the access hole into the frame as shown.

4. Install Hitch:

   • Raise the hitch into position between the frame rail and fasteners. Install the remaining fasteners as shown. Ensure the brackets sit flush on the frame.

5. Reinstall Step Bumper:

   • Reinstall the step bumper and secure it in its original position.

6. Tighten Fasteners:

   • Torque all fasteners to the specified values:
     • 1/2"-13 GR5: 75 Lb.-Ft. (102 N*M)
     • 1/2"-20 GR5: 55 Lb.-Ft. (75 N*M)
     • 7/16"-14 GR5: 50 Lb.-Ft. (68 N*M)

Hardware List:

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

Safety Notes:

• Regularly inspect all fasteners and the hitch ball to ensure they remain 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.
• Always observe safety precautions and wear eye protection when working beneath the vehicle.
• Do not cut access or attachment holes with a torch.

Compliance:

• This product complies with SAE J684, V.E.S.C. Regulation V-5, and safety requirements of the State of New York.

Additional Notes:

• Check the hitch frequently to ensure all fasteners remain tight.

Installation Instructions for T-Connector Adapter

Part Numbers:

• 118381

Wiring Access Location:

• Underneath the vehicle, behind the bumper, on the driver’s side.

Tools Required:

• None specified.

Step-by-Step Instructions:

For Full-Size Dodge Vans Without Factory 7-Way:

1. Locate the vehicle’s trailer harness connector (A), found under the vehicle, behind the bumper, on the driver’s side (Fig. 1).

2. Remove the protective cap (B) from the connector (A) and save it.

   • Ensure the mating surfaces of the connectors are free of dirt. Clean if necessary.

3. Connect the T-Connector adapter end (C) to the vehicle’s connector (A).

   • Ensure the T-Connector is fully inserted and the locking tabs are in place.

4. Place the protective cap (B) on the remaining plug end (Fig. 1).

5. Skip to step 7 for final installation instructions.

For Vehicles with a Factory 7-Way (Durango, Dakota, Full-Size Ram, Jeep Grand Cherokee, Dodge Vans):

1. Remove the screws holding the 7-way trailer tow bracket in place (Fig. 2).

2. Pull out the 7-way connector to access the plug on its back.

   • Slide the red locking tab to the unlocked position and separate the connector (A) (Fig. 3).

3. Connect the T-Connector adapter in between the separated halves (B).

   • Slide the red locking tab back to the locked position.

4. Route the 4-flat connector away from the 7-way bracket.

5. Push the 7-way connector back into the bracket and reinstall the screws.

Final Steps for All Installations:

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.
• Protective cap.

Safety Notes:

• Ensure all connections are clean and securely fastened.
• Test the installation after completing all steps to verify functionality.
• Do not exceed the specified amperage rating to prevent damage or fire.

Manufacturer Notes:

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