Installation Instructions for Ford Freestyle, Taurus X, and Mercury Montego/Sable

Part Numbers:

• 75299N
• 44529N
• 87102N

Tools Required:

• Wrenches: 3/4", 13mm, 15mm
• Drill Bits: None

Wiring Access Location:

• SUV1, SUV2, PC3, PC4

Step-by-Step Instructions:

1. Remove Exhaust Hanger:

   • Detach the exhaust hanger bracket from the driver’s side frame rail and lower the carbon canister on the passenger side (if present).

2. Install Carriage Bolts and Blocks:

   • Insert 7/16" x 1-1/4" GR5 carriage bolts with spacer blocks through access holes at the end of the frame.
   • Place additional spacer blocks and secure bolts as shown in the diagram.

3. Position the Hitch:

   • Raise the hitch into position, aligning it with the installed carriage bolts and the frame rail.

4. Attach Forward Fasteners:

   • Secure the forward holes using M8 x 1.25 x 35mm CL9.8 bolts with conical toothed washers.

5. Tighten Fasteners:

   • Tighten all fasteners as follows:
     • M8 fasteners: 23 lb-ft (31 N·m)
     • 7/16" fasteners: 50 lb-ft (68 N·m)

6. Reattach Exhaust Hanger:

   • Reattach the exhaust hanger bracket and the carbon canister.

7. Final Inspection:

   • Ensure all bolts are tightened to specification, and inspect the installation for any interference with surrounding components.

Hardware List:

• (4) 7/16"-14 x 1-1/4" GR5 Carriage Bolts
• (4) 0.25" x 1.00" x 2.00" Spacer Blocks
• (4) 7/16" Conical Toothed Washers
• (4) 7/16"-14 Hex Nuts
• (2) M8 x 1.25 x 35mm CL9.8 Hex Bolts
• (2) M8 Conical Toothed Washers

Torque Specifications:

• Tighten all M8 CL9.8 fasteners to 23 lb-ft (31 N·m).
• Tighten all 7/16" GR5 fasteners to 50 lb-ft (68 N·m).

Safety Notes:

• Check the hitch frequently to ensure all fasteners and the ball are properly tightened.
• If the hitch is removed, plug all holes in the trunk pan or other body panels to prevent water and exhaust fumes from entering.
• Replace any damaged hitch or ball immediately.
• Follow all safety precautions when working beneath the vehicle, and wear eye protection.
• Do not cut access or attachment holes with a torch.

Specifications:

• Hitch Type and Weight Ratings:
  • Weight Distributing: Max Trailer Weight 4,000 lbs (1,814 kg), Max Tongue Weight 400 lbs (181 kg).
  • Weight Carrying (Ball Mount): Max Trailer Weight 3,500 lbs (1,588 kg), Max Tongue Weight 350 lbs (159 kg).
• Complies with safety specifications and requirements for connecting devices and towing systems of the State of New York, V.E.S.C. Regulation V-5, and SAE J684.

Installation Instructions for T-Connector Adapter

Part Numbers:

• 118395

Tools Required:

• Trim Panel Puller
• Drill with a 3/32" Drill Bit

Step-by-Step Instructions:

1. Access the Rear Trim Panels:

   • Ford Freestyle: Open the rear hatch and temporarily remove the rear threshold plate. Partially remove the rear interior trim panels on both the driver’s and passenger’s sides. Several trim panel fasteners need to be removed to detach the panels. Set aside all removed items carefully.
   • Ford Five Hundred: Open the trunk and temporarily remove the rear threshold plate. Partially remove the felt trunk liner behind the taillights.

2. Locate the Vehicle’s Wiring Harness:

   • On both the driver’s and passenger’s sides of the vehicle, locate the taillight wiring harness. The wiring harness has a connection point matching the T-Connector adapter.
   • Separate the connectors carefully, ensuring no damage to the locking tabs. Ensure all connector surfaces are clean and free of dirt.

3. Install the T-Connector:

   • On the driver’s side, insert the T-Connector with the yellow wire between the vehicle wiring connectors. Lock it into place, ensuring the connectors are fully inserted and secured with the locking tabs.
   • Route the T-Connector end with the green wire to the passenger’s side behind the panels and along the threshold. Repeat the connection process on the passenger’s side using the T-Connector with the green wire.

4. Ground the White Wire:

   • Ford Freestyle: Drill a 3/32" hole near the connector and secure the white wire using the provided eyelet and screw.
   • Ford Five Hundred: Locate the existing ground stud on the driver’s side. Loosen the bolt, place the screw eyelet on the stud, and retighten the bolt.

   Caution:

   • Verify what is behind any surface before drilling to avoid damage to the vehicle or personal injury. Do not drill into exposed surfaces.

5. Reassembly:

   • Ford Freestyle: Route the 4-flat connector from below the driver’s side trim panel into the rear storage compartment. Store it there when not in use. Reinstall the plastic trim panels, threshold, storage covers, floor covering, and any other items removed during installation, ensuring no wires are pinched or cut.
   • Ford Five Hundred: Route the 4-flat connector from below the threshold plate into the trunk and store it there when not in use. Reinstall the felt trunk liner, threshold, and other items removed during installation, ensuring no wires are pinched or cut.

6. Testing the Installation:

   • Verify the T-Connector functionality using a test light or trailer. Ensure all connections are complete for the T-Connector to function properly.

   Specifications:

   • Max. stop/turn light: 7.5 amps
   • Max. tail lights: 7.5 amps

Safety Notes:

• Overloading circuits can cause fires. Do not exceed the lower of the towing manufacturer’s rating or the unit specifications.
• Follow all warnings and instructions provided.

Manufacturer Notes:

• Refer to the vehicle owner’s manual and instruction sheet for additional guidance.