Installation Instructions for Ford Explorer and Mercury Mountaineer

Part Numbers:

• 44542
• 75437
• 70648

Tools Required:

• Wrenches: 3/4", 13mm
• Pull Wire (Provided)
• Cable Tie (Provided)
• Hammer
• Drill Bits: None

Wiring Access Location:

• SUV1, SUV2

Step-by-Step Instructions:

1. Remove Electrical Bracket:

   • Detach the electrical bracket from the impact bumper.
   • Disconnect the rubber electrical connector from the metal bracket.
   • Replace the bolt and return the bracket to the vehicle owner.

2. Install Forward Carriage Bolt:

   • Use the pull wire to insert the forward carriage bolt and block through the access slot on either side of the frame rail.

3. Position Hitch:

   • Raise the hitch into position carefully, ensuring the carriage bolt and block do not push back into the frame.
   • Hand-tighten the conical washer and hex nut.

   Note: For some vehicles, the rearward attachment hole may show minor deformation. Use a hammer to flatten the frame rail if needed for hitch alignment.

4. Install Rearward Carriage Bolt:

   • Use the pull wire to insert the remaining carriage bolt and block through the same access slot on each side of the frame rail.

5. Tighten Fasteners:

   • Use a torque wrench to tighten all 1/2"-13 fasteners to 75 lb-ft.

6. Secure Electrical Wiring:

   • Attach existing electrical wiring to the round cross tube using the provided cable ties.
   • Fasten the wiring in a way that allows future access.

7. Reinstall Spare Tire (if removed):

   • Raise and secure the spare tire to its original position.

Hardware List:

• (4) 1/2"-13 x 2.00" Carriage Bolts
• (4) Blocks
• (4) 1/2" Conical Washers
• (4) 1/2"-13 Hex Nuts
• (2) Pull Wires
• (2) Cable Ties

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 Carrying (Ball Mount): Max Trailer Weight 5,000 lbs (2,268 kg), Max Tongue Weight 500 lbs (227 kg).
  • Weight Distributing: Max Trailer Weight 8,000 lbs (3,628 kg), Max Tongue Weight 800 lbs (363 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 Circuit Protected Converter

Part Numbers:

• 119178

Wiring Access Location:

• Not specified in the document.

Tools Required:

• Drill (3/32” Drill Bit)
• Wire Crimpers
• Philips Head Screwdriver
• Test Probe

Step-by-Step Instructions:

1. Using a circuit tester, carefully probe one wire at a time to determine vehicle functions.

   • Caution: Do not probe across two wires or across a wire and vehicle structure to avoid damaging electronic components.

2. Disconnect and isolate the vehicle's negative (-) battery terminal.

   • Warning: Follow all warnings and precautions printed on the tow vehicle’s battery.

3. Attach the trailer wiring to the vehicle as shown in the illustration using splices.

4. Locate a suitable grounding point.

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

5. Mount the circuit-protected converter near the left tail light in the trunk or on the frame rail under the vehicle.

   • Mount with the wiring directed downward or sideways if downward is not possible.

6. Reconnect the vehicle's negative (-) battery terminal.

7. Testing Procedure:

   • Attach the ground lead of a circuit tester to the exposed ground terminal of the 4-flat end.
   • Activate the tow vehicle’s left turn, right turn, tail, and stop lights one at a time. Test each to confirm proper functionality.
   • Warning: Ensure all connections are complete for proper function. Test installation with a trailer or test light.

8. Secure all loose wires with cable ties.

   • Warning: Do not overload circuits to prevent fires. Adhere to these limits:
     • Max stop/turn light: 1 per side (2.1 amps)
     • Max tail lights: (7.5 amps)

Hardware List:

• Not detailed in the document.

Safety Notes:

• Wear safety glasses and follow safety precautions.
• Disconnect the negative (-) cable before wiring.
• Securely ground to the vehicle chassis or an existing ground stud.
• Use on 12-volt negative ground systems only.

Specifications:

• Max stop/turn light: 1 per side (2.1 amps)
• Max tail lights: (7.5 amps)
• Secure wiring with cable ties after installation.

Manufacturer Notes:

• Read and follow all vehicle warnings and instructions.
• Refer to the vehicle's owner manual and manufacturer materials for additional guidance.