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 for Mercury Milan

Part Numbers:

• 118502

Tools Required:

• Drill (3/32” Drill Bit)
• Philips Head Screwdriver
• 10mm Socket & Ratchet or 10mm Wrench
• Wire Crimpers
• Wire Cutters

Step-by-Step Instructions:

1. Locate the Vehicle Wiring:

   • Inside the vehicle’s rear cargo area, partially remove the plastic threshold cover and felt trunk liner.
   • Locate the connection points matching the ends of the T-Connector adapter on the back of each vehicle taillight housing.

2. Install the T-Connector on the Driver’s Side:

   • Disconnect the vehicle’s taillight connectors carefully to avoid damaging the locking tabs.
   • Insert the T-Connector ends containing the yellow and brown wires between the separated connectors on the driver’s side.
   • Ensure the connectors are fully inserted with the locking tabs in place.

3. Route the Passenger-Side T-Connector:

   • Route the T-Connector containing the green wire below the threshold cover to the passenger’s side taillight housing.
   • Repeat step 2 using the T-Connector ends containing the green wire.

4. Connect the Power Wire:

   • Inside the trunk, connect the black 12-gauge wire to the red wire from the T-Connector black box using the supplied yellow butt connector.

5. Ground the White Wire:

   • Locate a suitable grounding point near the connector, such as the vehicle’s frame or cross member.
   • Clean the grounding area to remove dirt and rustproofing.
   • Drill a 3/32” hole and secure the white wire using the provided eyelet and screw.
   • Caution: Verify what is behind the surface before drilling to avoid damage or injury. Do not drill into exposed surfaces.

6. Route the Black Wire to the Battery:

   • Route the black wire from the rear cargo area into the engine compartment up to the vehicle’s battery.
   • Avoid hot pipes, heat shields, fuel tanks, or areas that may pinch or damage the wire.

7. Connect to the Vehicle Battery:

   • Disconnect the vehicle’s negative (-) battery cable.
   • Cut the fuse holder wire and attach the ring terminal to the positive (+) battery cable.
   • Connect the other end of the fuse holder to the black 12-gauge wire using the yellow butt connector.
   • Reconnect the negative (-) battery cable and install the 10-amp fuse into the fuse holder.

8. Secure the Wiring:

   • Secure the remainder of the T-Connector harness using the provided cable ties to prevent damage or rattling.
   • Mount the T-Connector black box on a flat, clean surface using the double-sided tape provided.

9. Reassemble the Vehicle:

   • Replace the trunk threshold and felt trunk liner removed during installation.

10. Test the Installation:

    • Test and verify the installation with a test light or trailer to ensure proper functionality.

    Specifications:

    • Max. stop/turn light: 1 per side (2.1 amps)
    • Max. tail lights: (5.6 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:

• Store the 4-flat connector in the rear cargo area when not in use.
• Refer to the vehicle owner’s manual for additional guidance.