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 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