Installation Instructions for Ram 1500

Part Numbers:

• 75232
• 87694
• 44782

Applications:

• 2011-Current Ram 1500 (Visit the manufacturer's website for the most up-to-date application years and trim levels.)

Tools Required:

• Ratchet
• Torque Wrench
• Safety Glasses
• Sockets: 22mm, 3/4"

Installation Time:

• Approximately 40 minutes (for professional installers)

Step-by-Step Instructions:

1. Lower Spare Tire:

   • Lower the spare tire for easier installation.

2. Remove Existing Fasteners:

   • Remove the M14 bolt connecting the bumper beam to the frame rail on both the driver and passenger sides of the vehicle.
   • Retain the bolts for reinstallation later.

3. Fishwire Carriage Bolts and Spacers:

   • Use the reverse fishwire technique to insert carriage bolts and spacers (items 1 and 4) through the large round holes in the driver and passenger frame rails.

4. Install Additional Fasteners:

   • Fishwire additional carriage bolts and spacers (items 1 and 3) through the ends of the bumper beam and out of the slot on the forward side of the beam.

5. Raise Hitch into Position:

   • Lift the hitch into place and loosely install the conical washers, spacers (items 2, 5, and 6), and hex nuts onto the previously installed carriage bolts.
   • Ensure spacers are positioned between the frame and hitch.

6. Reinstall Fasteners:

   • Reinstall the M14 fasteners removed in step 2.

7. Tighten Fasteners:

   • Use a torque wrench to tighten all fasteners to the following specifications:
     • 1/2" bolts: 75 lb-ft (102 N·m)
     • M14 fasteners: 122 lb-ft (165 N·m)

8. Reposition Spare Tire:

   • Raise the spare tire back into its original position.

Hardware List:

• (4) 1/2-13 x 1.75 GR5 Carriage Bolts
• (4) 1/2" Conical Washers
• (2) 0.25 x 1.50 x 3.00 Spacers
• (2) 0.25 x 1.00 x 3.00 Spacers
• (2) 0.188 x 1.50 x 2.00 Spacers
• (4) 1/2-13 Hex Nuts
• (4) 1/2" Fishwires

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: Max Trailer Weight 10,000 lbs (4,536 kg), Max Tongue Weight 1,000 lbs (454 kg).
  • Weight Distributing: Max Trailer Weight 12,000 lbs (5,443 kg), Max Tongue Weight 1,200 lbs (544 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 Trailer Light Wiring Kit

Part Number:

• 20252

Tools Required:

• Hot Air Gun or Appropriate Heat Source
• Wire Crimpers
• Drill (3/32” Drill Bit)
• Phillips Head Screwdriver
• Circuit Tester

Step-by-Step Instructions:

Step 1: Locate the Taillight Wiring Harness

1. Access the vehicle's taillight wiring harness.
2. Using the provided instructions, identify the appropriate wires for connection:
   • Green Wire: Right Turn & Stop
   • Yellow Wire: Left Turn & Stop
   • Brown Wire: Taillights
   • White Wire: Ground

Step 2: Make the Electrical Connections

1. Match the color-coded wires from the wiring kit to the corresponding vehicle wires.

   • Use a circuit tester to verify each wire's function before connecting.
   • CAUTION: Test one wire at a time to prevent damage to electronic components.

2. Connect the wires using the provided insulated butt connectors:

   • Strip the ends of each wire and seat them properly in the connector.
   • Use a crimping tool designed for insulated splices to secure the connections.

3. Heat the connectors:

   • Apply heat directly to the center of each splice using a hot air gun.
   • Work from the center outward until the tubing recovers and adhesive flows.
   • Allow the connections to cool before inspecting for integrity.

Step 3: Ground the System

1. Locate a grounding point near the wiring harness, such as the vehicle frame or cross member.
   • Do not drill into the vehicle floor or bed.
2. Clean the area to remove dirt, rust, or undercoating.
3. Drill a 3/32" hole at the grounding point and secure the white wire using the provided eyelet and screw.

Step 4: Verify the Installation

1. Test all connections using a circuit tester or trailer:
   • Verify the functionality of taillights, turn signals, and brake lights.
   • Ensure all connections are complete and secure.
2. If issues are identified, double-check the wiring and connections for errors.

Step 5: Store the 4-Flat Connector

• Store the 4-flat connector in the rear cargo area when not in use to protect it from damage and environmental exposure.

Warnings and Notes:

• WARNING: Overloading a circuit can cause fires. Do not exceed the following limits:
  • Stop/Turn Lights: 7.5 amps (1 per side)
  • Tail Lights: 7.5 amps
• WARNING: Always verify what is behind any surface before drilling to avoid vehicle damage or injury.
• NOTE: Trailer lighting that requires more than 7.5 amps per circuit must use a Trailer Light Power Converter.
• NOTE: If your trailer requires a plug other than the 4-flat, consult your dealer for optional 6-way or 7-way adapters.

Maintenance:

• Inspect the wiring harness periodically for damage, corrosion, or loose connections.
• Reapply heat to connectors if the adhesive seal weakens.

Specifications:

• Maximum Load:
  • Stop/Turn Lights: 7.5 amps (1 per side)
  • Tail Lights: 7.5 amps
• Recommended Grounding Hole Size: 3/32 inches