Installation Instructions for Mazda 6 Sedan & 5-Door, Ford Fusion, Mercury Milan, Lincoln Zephyr, and Lincoln MKZ

Part Numbers:

• 77152
• 24775
• 60846

Wiring Access Location:

• PC3, PC4

Tools Required:

• Pull Wire (Provided)
• Wrenches: 12mm, 13mm, 3/4"
• Drill Bits: 1/2"

Specifications:

• Max Gross Trailer Weight: 2,000 lb. (908 kg)
• Max Tongue Weight: 200 lb. (90.8 kg)
• Note: Do not exceed towing vehicle manufacturer’s rating.

Step-by-Step Instructions:

1. Lower Muffler:

   • Remove three (3) rubber isolator hangers: two near the muffler end and one forward of the rear axle.
   • Remove two (2) rubber plugs from the trunk pan if present.

2. Remove Existing Fasteners:

   • Remove the 8mm bolts located inside the frame rail on the bulkhead on both sides of the vehicle. Discard these bolts.

3. Position Hitch:

   • Slide the hitch above the tailpipes, ensuring the inner bumper straps slide under the fascia.
   • Install the M8 bolts loosely through the upright brackets.

4. Prepare Bumper Slots:

   • If the vehicle bumper has slots aligning with the holes in the inner bumper strap, proceed to Step 5.
   • Otherwise, use the hitch’s inner bumper straps as a template to drill two (2) 1/2” holes in the bumper.

5. Install Carriage Bolt and Block:

   • Fishwire the carriage bolt and block through the inner bumper structure and carefully pull the fastener through the slot or drilled hole in the bumper and hitch.
   • Install the conical toothed washer and nut.

   Torque Specifications:

   • Tighten all 1/2”-13 GR5 fasteners to 75 Lb.-Ft. (102 N*M).
   • Tighten all M8 fasteners to 25 Lb.-Ft. (34 N*M).

6. Install Hex Bolt and Block:

   • Insert the hex bolt and block through the trunk pan holes if present. If not, remove the spare tire and use the hitch as a template to drill two (2) 1/2” holes in the trunk pan. Install the fasteners as shown.

   Torque Specifications:

   • Tighten all 1/2”-13 GR5 fasteners to 75 Lb.-Ft. (102 N*M).

7. Seal Holes:

   • Seal all trunk pan holes to prevent water or exhaust fumes from entering.

8. Reinstall Muffler:

   • Attach the muffler to the three (3) rubber isolator hangers.

9. Reinstall Spare Tire:

   • Place the spare tire back in the trunk.

Hardware List:

• (2) Hex Bolts: 1/2”-13 x 1-1/2” GR5
• (4) Conical Toothed Washers: 1/2”
• (2) Carriage Bolts: 1/2”-13 GR5
• (2) Blocks: 1/4” x 1” x 2”
• (2) M8 x 1.25 x 35mm CL9.8 Bolts
• (2) Blocks: 3/16” x 1-1/2” x 2”

Safety Notes:

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

Drawbar:

• Drawbar Kit: 3592 (or 3594 for Mazda 6 only)
• Important: The drawbar must be used in the rise position only.

Compliance:

• This product complies with SAE J684, V.E.S.C. Regulation V-5, and safety requirements of the State of New York.

Installation Instructions for T-Connector Adapter

Part Numbers:

• 118405

Wiring Access Location:

• Rear taillight assemblies and under the vehicle near the bumper.

Tools Required:

• Drill with 3/32” drill bit.
• Philips head screwdriver.
• 10mm socket and ratchet or wrench.
• Wire crimpers and cutters.
• Trim panel remover.

Step-by-Step Instructions:

1. Access Vehicle Wiring:

   • Open the rear tailgate and remove the threshold panel.
   • For Mazda 6 Sedan and Coupe, remove the two 10mm nuts securing the driver’s side taillight housing. Pull the housing directly rearward to remove and set aside.

2. Prepare Wiring for Mazda 6 and Toyota Camry:

   • Locate the vehicle's wiring inside the trunk area by removing the plastic threshold cover and trunk liner.
   • Route the black 12-gauge wire through the opening in the taillight socket and behind the bumper to the engine compartment.

3. Driver’s Side Connection:

   • Attach the T-Connector containing the yellow and red wires between the vehicle wiring connectors behind the driver’s side taillight. Ensure the connectors are fully inserted and secure the locking tabs.

4. Passenger’s Side Connection:

   • Route the T-Connector with the green wire to the passenger side beneath the vehicle threshold cover.
   • Repeat step 3 using the T-Connector ends with the green wire.

5. Ground Connection:

   • Locate a suitable grounding point near the connector:
     • Option 1: Clean the area, drill a 3/32” hole, and secure the white wire with the provided eyelet and screw.
     • Option 2: Use an existing ground stud. Loosen the bolt, attach the eyelet, and retighten.

6. Routing the Power Wire:

   • Route the black 12-gauge wire from the taillight area to the engine compartment, avoiding hot pipes, heat shields, and the fuel tank.

7. Connect to the Battery:

   • Disconnect the negative battery cable.
   • Install the yellow fuse holder on the positive battery cable using the provided ring terminal and yellow butt connector.
   • Connect the other end of the fuse holder to the black 12-gauge wire using the provided yellow butt connector.

8. Reconnect Battery and Test Installation:

   • Reconnect the negative battery cable.
   • Insert the 10-amp fuse into the fuse holder.
   • Test the installation with a test light or trailer.

9. Final Steps:

   • Secure the T-Connector black box using the provided double-sided tape.
   • Use cable ties to secure the remaining harness to prevent damage or rattling.
   • Reinstall all panels, liners, and covers removed during the process.

   Specifications:

   • Max. stop/turn light: 1 per side (2.1 amps).
   • Max. tail lights: (4.2 amps).

Hardware List:

• T-Connector adapter.
• Black converter box.
• Yellow fuse holder with 10-amp fuse.
• Eyelet and screw.
• Double-sided tape.
• Cable ties.

Safety Notes:

• Ensure all connections are complete to avoid circuit overload.
• Test thoroughly after installation to confirm functionality.

Manufacturer Notes:

• Follow all vehicle warnings and installation instructions.
• Use a test light or trailer to confirm proper installation.
• Consult the vehicle owner’s manual for additional details.