Installation Instructions for Pontiac Aztek and Buick Rendezvous

Part Numbers:

• 44538
• 75430
• 87004

Tools Required:

• Wrenches: 9/16", 11/16", 3/4"
• Drill Bits: 3/8"

Wiring Access Location:

• SUV1, SUV2

Step-by-Step Instructions:

1. Lower Exhaust:

   • Detach the rubber exhaust hanger from the hanger bracket to lower the exhaust, which may ease installation.

2. Install Carriage Bolts:

   • Install a block and carriage bolt up through the rearmost slot in the vehicle frame rail and down through the forward slot in the frame rail on both sides.
   • Install another block and carriage bolt up through the rearmost slot and back down through the same slot on both sides.
   • Note: Ensure that blocks installed in Steps 1 and 2 do not overlap inside the frame.

3. Position Hitch:

   • Raise the hitch into position on the carriage bolts.
   • Ensure the rear face of the hitch end plate contacts the lip of the vehicle end panel as shown in the diagram.
   • Install conical toothed washers and nuts finger-tight.

4. Drill Holes:

   • Using a 3/8” drill bit, drill through the holes in the hitch end plate into the lip of the vehicle end panel (two places on each side).

5. Install Fasteners:

   • Insert 3/8”-16 hex bolts with flat washers, lock washers, and nuts into the drilled holes as shown.
   • Tighten all 3/8”-16 fasteners to 30 lb-ft using a torque wrench.

6. Reattach Exhaust:

   • If the exhaust was lowered, raise it back into position.
   • Note: If additional exhaust clearance is required, bend the welded exhaust hanger bracket downward.

7. Final Tightening:

   • Tighten all 1/2”-13 fasteners to 75 lb-ft using a torque wrench.

Hardware List:

• (4) 1/2”-13 x 1-3/4” Carriage Bolts
• (4) 3/8”-16 x 1-1/4” Hex Bolts
• (4) 1/2” Conical Toothed Washers
• (4) 3/8” Flat Washers
• (4) 3/8” Lock Washers
• (4) 3/8”-16 Hex Nuts
• (4) 1/4” x 1” x 3” Spacer Blocks

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 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 Carrying: 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-One® T-Connector

Part Numbers:

• 118383

Tools Required:

• Trim Panel Remover
• Drill (3/32” Drill Bit)
• Utility Knife
• Philips Head Screwdriver
• Test Probe

Step-by-Step Instructions:

1. Remove Storage Compartment Doors:

   • Open the rear door of the vehicle.
   • Temporarily remove the rear storage compartment doors and the rear threshold plate.

2. Remove Taillight Assemblies:

   • Remove the two screws on the inboard side of each taillight assembly.
   • Pull the rubber grommets away from the vehicle’s body to expose the electrical connectors.
   • Gently lift the locking tabs and separate the electrical connectors.

3. Prepare the Grommets:

   • Slit the grommets with a utility knife as needed to allow the T-Connector wiring to pass through.

4. Route the Passenger Side T-Connector:

   • Partially remove the side rear trim panels. Remove two cargo hold brackets on each side.
   • Starting on the right side, route the connectors with the green wire up through the storage compartment, behind the rear trim panel, and out through the passenger-side rear taillight.
   • Plug the T-Connector between the mating plug on the taillight socket and the vehicle’s wiring harness.

5. Ground the White Wire:

   • Locate a suitable grounding point.
   • Drill a 3/32” hole and secure the white wire using the eyelet and screw provided.
   • Caution: Do not drill into exposed surfaces.

6. Route the Driver’s Side T-Connector:

   • Route the connectors with the yellow and brown wires through the right-side storage compartment and behind the right-side rear trim panel.
   • Continue routing underneath the threshold, behind the left-side rear trim panel, and out the driver’s side rear taillight.
   • Plug the T-Connector between the mating plug on the taillight socket and the vehicle’s wiring harness.

7. Seal and Reseat Grommets:

   • Place the T-Connector wiring in the slit of the grommet and seal as needed.
   • Reseat the grommets securely.

8. Test the Installation:

   • Test the installation with a test light or trailer.

9. Reinstall Components:

   • Replace all trim panels, storage compartment doors, and taillight housings.
   • Position the wire harness between the taillight housing and the vehicle body.
   • Store the 4-flat connector in the jack storage compartment when not in use.

   Warning:

   • This unit is rated for 7.5 amps per circuit. Do not exceed the stated product ratings.
   • Refer to the vehicle owner’s manual and instruction sheet for additional details.

Safety Notes:

• Always wear safety glasses and follow proper safety precautions during installation.
• Avoid routing wires near sharp edges or hot components that may damage the harness.
• Follow all vehicle warnings and installation instructions carefully.

Manufacturer Notes:

• Store these instructions for future reference.
• Refer to the vehicle owner’s manual for additional details.