Installation Instructions for Ford F350/F450/F550 (2019–Current)

Part Numbers:

• 41953
• 96953
• CQT41953

Wiring Access Location:

• Not specified

Tools Required:

• Wrenches: 13/16", 7/8", 21mm, 24mm
• Ratchet
• Torque Wrench
• 6" Socket Extension
• Safety Glasses
• Clamp

Installation Time:

• Approximately 45 minutes for professional installers

Step-by-Step Instructions:

1. Install Side Brackets:

   • Secure and align the side brackets with attachment holes on the frame rails using clamps.
   • Loosely install (6) M16 x 2.00 x 50mm bolts and (6) M16 flange locknuts per side using a 24mm socket.

2. Install Center Section:

   • Raise the center section into position.
   • Secure it to the side brackets using (4) 9/16"-18 x 1.75" bolts, (4) 9/16" hardened flat washers, and (4) 9/16"-18 flange locknuts per side.

3. Tighten Fasteners:

   • Torque all 9/16"-18 fasteners to 120 lb-ft (163 N*m).
   • Torque all M16 fasteners to 210 lb-ft (285 N*m).

4. Inspect Installation:

   • Check all fasteners and ensure the hitch is securely mounted.
   • Verify that the ball and fasteners are properly tightened.

Torque Specifications:

• 9/16"-18 GR5 bolts: 120 lb-ft (163 N*m)
• M16 x 2.00 bolts: 210 lb-ft (285 N*m)

Hardware List:

• (12) Bolts, M16 x 2.00 x 50mm
• (12) Flange Locknuts, M16 x 2.00
• (8) Bolts, 9/16"-18 x 1.75" GR5
• (8) Flange Locknuts, 9/16"-18
• (8) Hardened Flat Washers, 9/16"

Safety Notes:

• Regularly check the hitch to ensure all fasteners and the ball are secure.
• If the hitch is removed, plug all holes in the vehicle's frame to prevent water or exhaust fumes from entering.
• Replace any damaged hitch or ball immediately.
• Wear safety glasses and follow 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 (8,164 kg)
  • Max Tongue Weight: 2,700 lb (1,224 kg)
• Weight Distributing:
  • Max Gross Trailer Weight: 18,000 lb (8,164 kg)
  • Max Tongue Weight: 2,700 lb (1,224 kg)

Additional Notes:

• This product complies with V.E.S.C. Regulation V-5 and SAE J684 safety standards.
• Contact Horizon Global for technical assistance at 1-800-632-3290.

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

Installation Instructions for 4-Way to 7-Way Adapter and Brake Control Wiring

Tools Required:

• Phillips Head Screwdriver
• Drill with 3/32" Drill Bit
• 10mm Socket & Ratchet or Wrench
• Wire Crimpers
• Wire Cutters
• Test Light or Multimeter
• Cable Ties

Part 1: Install the 4-Way to 7-Way Adapter

Step-by-Step Instructions:

1. Mount the Adapter:

   • Choose a suitable mounting point on the vehicle, typically near the hitch.
   • Use the provided bracket and screws to secure the adapter.

2. Connect the 4-Flat Plug:

   • Plug the 4-flat connector on the adapter into the existing 4-flat plug on the vehicle.
   • This connection enables tail lights, left turn, and right turn signals.

3. Ground the Adapter:

   • Locate a clean, solid grounding point near the adapter.
   • Drill a 3/32" hole if necessary and secure the white ground wire from the adapter using the provided screw and eyelet.

4. Leave Additional Wires Disconnected:

   • The following wires will remain disconnected until Part 2:
     • Black Wire: Power from the battery.
     • Blue Wire: Brake control output.
     • Yellow Wire: Reverse light (optional; leave disconnected unless needed).

5. Test Initial Connection:

   • Use a test light or trailer to verify functionality of the 4-way connections (tail lights, turn signals).

Part 2: Install Brake Control Wiring

Step-by-Step Instructions:

1. Mount Circuit Breakers:

   • Install two 30A circuit breakers on the firewall or another suitable location near the battery.
   • Use self-tapping screws to mount them securely.

2. Route Power Wires:

   • Connect the black 12-gauge wire from the 7-way adapter to the auxiliary side of one circuit breaker (this powers the 7-way socket).
   • Run a heavy-gauge wire from the battery's positive terminal to the battery side of this circuit breaker, using a ring terminal.
   • Run another heavy-gauge wire from the battery's positive terminal to the auxiliary side of the second circuit breaker (for the brake controller).

3. Install the Brake Controller:

   • Mount the brake controller under the dash on a firm surface.
   • Use the following connections:
     • Red Wire: Connect to the cold side of the brake switch (active only when the brake pedal is pressed).
     • Blue Wire: Connect to the blue wire on the 7-way adapter for trailer brakes.
     • White Wire: Connect to a solid ground point on the vehicle body.
     • Black Wire: Connect to the auxiliary side of the second 30A circuit breaker (provides power to the brake controller).

4. Optional: Connect Reverse Light Circuit:

   • If the trailer has a reverse light circuit, connect the yellow wire from the 7-way adapter to the vehicle’s reverse light circuit.

5. Reconnect the Battery:

   • Reattach the negative battery cable and ensure all connections are secure.
   • Insert the fuses into both circuit breakers.

6. Secure All Wires:

   • Use cable ties to secure all loose wires and prevent damage or rattling.

7. Test the System:

   • Verify functionality of all circuits (running lights, turn signals, brake lights, and brake controller output).
   • If applicable, test the reverse light circuit.

Notes:

• Most installations will only require connecting the black and blue wires from the 7-way adapter.
• Leave the yellow wire disconnected unless the trailer has a reverse light or surge brake lockout circuit.
• Always adhere to safety guidelines and verify all connections before use.

Warning: Incorrect wiring can cause damage to the vehicle or trailer. Test all connections carefully before use.