Installation Instructions for Chevy/GMC 2500HD/3500HD (2001–2010)

Part Numbers:

• 45519
• 45719

Wiring Access Location:

• Not specified

Tools Required:

• Ratchet
• Torque Wrench
• Safety Glasses
• Sockets: 18mm, 21mm
• Pull Wire (if needed)

Installation Time:

• Approximately 25 minutes (for professional installers)

Step-by-Step Instructions:

1. Lower Spare Tire (Optional):

   • Lower the spare tire to allow easier access to the frame. This is not mandatory but recommended.

2. Remove Existing Bolts:

   • Remove the M14 bolts at the bottom of the frame that attach the bumper brackets.
   • Remove the M12 nuts and bolt plates from the sides of the frame. Retain these for reinstallation later.

3. Adjust Bumper Braces (2001–2007 Models Only):

   • Loosen the nuts at the bumper brace to allow it to swing away from the frame.

4. Position Hitch:

   • Raise the hitch into position and loosely install the M14 coarse-thread bolts and conical washers into the weld nuts on the bumper brackets.

5. Install Attachment Bars:

   • Place the attachment bars as shown in the provided diagrams and loosely bolt them to the hitch.

6. Reinstall Bumper Braces (if applicable):

   • For models equipped with bumper braces, swing them back into position and reinstall the bolt plates removed in step 2.

7. Install Additional Fasteners:

   • Install all remaining fasteners as shown in the diagrams. Note that not all fasteners may be used depending on your vehicle configuration.
   • For vehicles without a bumper, additional blocks and bolts are included in the kit for proper installation.

8. Tighten Fasteners:

   • Torque the fasteners as follows:
     • M14 x 1.5 bolts: 145 lb-ft (201 N*m)
     • M14 x 2.0 bolts: 115 lb-ft (156 N*m)
     • M12 x 1.75 bolts: 92 lb-ft (125 N*m)

9. Reinstall Spare Tire:

   • If the spare tire was removed, raise it back into position.

Torque Specifications:

• M14 x 1.5: 145 lb-ft (201 N*m)
• M14 x 2.0: 115 lb-ft (156 N*m)
• M12 x 1.75: 92 lb-ft (125 N*m)

Hardware List:

• (6) Hex Bolts, M14 x 1.50 x 45mm CL10.9
• (2) Blocks, 3/8" x 1.50" x 3.00"
• (6) Conical Washers, 5/8"
• (6) Hex Nuts, M14 x 1.50 CL10
• (2) Hex Bolts, M14 x 2.00 x 45mm CL10.9
• (6) Hex Bolts, M12 x 1.75 x 45mm CL10.9
• (10) Conical Washers, 1/2"
• (10) Hex Nuts, M12 x 1.75 CL10
• (2) Blocks, 1/4" x 1.50" x 2.00"
• (2) Attachment Bars (not in fastener kit)

Safety Notes:

• Regularly inspect the hitch to ensure all fasteners and the ball are secure.
• Replace any damaged hitch or ball immediately.
• If the hitch is removed, plug all holes in the frame to prevent water or exhaust fumes from entering.
• Always wear safety glasses and observe safety precautions when working beneath the vehicle.
• Do not cut access or attachment holes with a torch.

Specifications:

• Weight Carrying (Ball Mount):
  • Max Gross Trailer Weight: 18,000 lb (8,172 kg)
  • Max Tongue Weight: 2,000 lb (908 kg)
• Weight Distributing:
  • Max Gross Trailer Weight: 18,000 lb (8,172 kg)
  • Max Tongue Weight: 2,500 lb (1,135 kg)

Additional Notes:

• This product complies with V.E.S.C. Regulation V-5 and SAE J684 safety standards.
• For photo instructions, scan the QR code provided in the documentation or visit the manufacturer's website.

Installation Instructions for 7-Way Flat Pin Connector / 4-Flat Combo Adapter Harness

Part Numbers:

• 74682

Tools Required:

• Phillips Head Screwdriver
• Adjustable Wrench

Mounting Bracket Instructions:

1. Determine a suitable mounting point on the tow vehicle for the connector or use an existing mount. Ensure the trailer’s wire harness has sufficient length to reach this point.
2. Secure the mounting bracket on the rear of the tow vehicle or to the plate attached to the hitch cross tube using the self-tapping screws provided.
   • Caution: Do not drill into the hitch cross tube to avoid damage to the hitch or personal injury. Do not drill into any exposed surfaces. Refer to the hitch owner’s manual or instruction sheet for recommendations and limitations.

Socket Instructions:

1. Install the 7-way Blade Socket (connector) onto the mounting bracket using the screws and nuts provided.
2. Plug the OEM factory-equipped car-end socket harness into the 7-way Blade Car Socket.
3. Insert the 4-flat connector into the slot in the bracket.
4. Tighten all screws securely.

Safety Notes:

• All connections must be completed to ensure proper functionality. Test and verify the installation using a test light, circuit tester, or trailer.
• Warning: Overloading circuits can cause fires. DO NOT exceed the lower of the towing manufacturer’s rating or:
  • Max Right Turn, Left Turn, Stop, and Tail Light Circuits: 7.5 amps
  • Max (+) Battery, Reverse, and Electric Brake Circuits: 30 amps
• Consult the vehicle’s owner’s manual and instruction sheet for additional information. Additional fusing may be required.

Technical Support:

For technical support and assistance, our team of experts is available to help. You can reach our tech support by visiting www.trailerjacks.com or calling 877-869-6690.

Warning: Improper use or failure to follow instructions may result in property damage, serious injury, or death. Always consult your vehicle and trailer manuals for compatibility and installation guidelines.