Installation Instructions for Chrysler Town & Country, Dodge Grand Caravan, VW Routan, and Ram C/V Tradesman

Part Numbers:

• 75579
• 87451
• 44586

Tools Required:

• Wrenches: 13mm, 15mm, 18mm
• Drill Bits: None

Wiring Access Location:

• SUV1, SUV2

Step-by-Step Instructions:

1. Lower Exhaust:

   • Remove the bolt attaching the rearmost hanger bracket to the passenger-side frame rail.
   • Retain the bolt for reinstallation.

2. Install Plastic Loom (if applicable):

   • Snap the plastic loom in place over the air conditioning line near the bolt (if present) to protect it. See Figure 2.

3. Remove Existing Bolts:

   • On the driver's side, remove three (3) bolts from the frame rail.
   • On the passenger's side, remove two (2) bolts.
   • Retain all bolts for hitch installation.

4. Remove Plastic Rivet (Driver's Side):

   • Remove the plastic rivet securing the plastic mud flap to the driver's side frame rail.
   • After hitch installation, trim the plastic corner of the mud flap if necessary.
   • Do not reinstall the plastic rivet.

5. Raise the Hitch:

   • Position the hitch and secure it with the bolts removed in Step 3.
   • Hand-tighten the fasteners.

6. Align Hitch:

   • Push the hitch toward the driver's side so the passenger-side bracket contacts the trunk pan.

7. Tighten Fasteners:

   • Torque all M10 CL10.9 fasteners to 53 lb-ft (72 N·m).
   • Torque all M12 CL10.9 fasteners to 92 lb-ft (125 N·m).

8. Reinstall Exhaust:

   • Raise the exhaust back into position and reinstall the bolt removed in Step 1.

   Note: Rotating the exhaust hanger bracket before tightening will provide additional clearance between the hitch bracket and exhaust.

Hardware List:

• (5) Existing M10 Bolts (from vehicle frame)
• (2) Existing M12 Bolts (from vehicle frame)

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 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 Distributing: Max Trailer Weight 5,000 lbs (2,270 kg), Max Tongue Weight 500 lbs (227 kg).
  • Weight Carrying (Ball Mount): Max Trailer Weight 4,000 lbs (1,816 kg), Max Tongue Weight 400 lbs (182 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 7-Way T-One® T-Connector Kit

Part Numbers:

• 22121

Tools Required:

• Trim Panel Puller
• Ratchet
• 10mm Socket
• Wire Strippers/Crimpers
• Heat Gun
• Test Probe or Voltmeter
• Phillips Head Screwdriver

Hardware Included:

• Cable Ties (24 - 8.5”, 1 - 14.5”)
• Wire Tap (1)
• 25 AMP Fuse (1)
• 30 AMP Fuse (1)
• Yellow Butt Connectors (7)
• Ring Terminals (4)
• Fuse Holders (2)
• Self-Tapping Screw (1)
• Breaker Boot (1)
• Circuit Breakers (20 AMP, 30 AMP)

Step-by-Step Instructions:

1. Prepare the Vehicle:

   • Disconnect and isolate the vehicle’s negative battery terminal.
   • Locate the positive battery post underneath the hood on the driver’s side.
   • Open the rear hatch and remove the taillight assemblies on both sides of the vehicle.

2. Connect Driver-Side T-One® Connector:

   • In the driver-side taillight pocket, connect the T-One® Connector with yellow and brown wires to the vehicle’s taillight wiring harness.
   • Locate a suitable grounding point near the ModuLite® box, such as the vehicle frame or cross member.
   • Drill a 3/32” hole and secure the white wire using the provided eyelet and screw.

3. Mount the ModuLite® Box:

   • Use the supplied double-sided tape and/or cable ties to mount the ModuLite® box securely.

4. Route Passenger-Side T-One® Connector:

   • Route the T-One® Connector with green and red wires behind the rear bumper fascia to the passenger-side taillight pocket.
   • Connect the T-One® Connector to the passenger-side taillight wiring harness.

5. Install the Body Harness:

   • Underneath the vehicle on the driver’s side, route the body harness with red, black, and blue wires along the frame rails to the engine compartment.
   • Use the provided butt connectors to connect the body harness wires to the ModuLite® box.

   Warning: Avoid hot pipes, heat shields, the fuel tank, or any areas that may pinch or break the wire.

6. Connect to Battery:

   • Route the black wire to the vehicle’s positive battery post. Connect it using the 30 AMP fuse holder, butt connector, and ring terminal.
   • Route the red wire to the positive battery post. Connect it using the 25 AMP fuse holder, butt connector, and ring terminal.

7. Install Brake Control Harness:

   • Route the brake control harness (white, blue, and black wires) through an existing grommet in the firewall into the engine compartment.
   • Connect the white wire to the chassis ground and the black wire to the battery with a 30 AMP circuit breaker.
   • Connect the blue wire to the body harness blue wire.

8. Install the 7-Way Connector:

   • Determine the mounting location for the 7-way connector.
   • Route the 7-way harness behind the rear bumper fascia to the mounting point.
   • Pin the 7-way connector and mount it securely (bracket not included).

9. Reassemble Components:

   • Replace all removed components, including trim panels and grommets. Seal altered grommets with silicone.

10. Reconnect the Battery:

    • Reconnect the negative battery cable.

11. Test Installation:

    • Test the installation with a test light or trailer to confirm proper functionality.

Specifications:

• Max. stop/turn/backup light: 2 per side (4.2 amps)
• Max. tail lights: 12 amps
• Max. 7-Way 12V power: 30 amps

Safety Notes:

• Overloading circuits can cause fires. Do not exceed the stated product ratings or vehicle manufacturer specifications.
• Always wear safety glasses and follow all safety precautions during installation.

Manufacturer Notes:

• Refer to the vehicle owner’s manual for additional details.
• Store these instructions for future reference.

Installation and Operation Instructions for the P3 Electronic Brake Control

Specifications:

• Supports 2, 4, 6, and 8 brake applications.
• Utilizes proportional braking with an inertial sensor.

Tools Required:

• Drill with a 1/8" bit.
• Screwdriver or nut driver.
• Wire crimp tool.
• Probe-type circuit tester.

Safety Notes:

1. Avoid mounting or activating RF-generating devices (e.g., cell phones) within 12 inches of the brake control.
2. Always adhere to the vehicle's Gross Combined Weight Rating (GCWR).
3. Do not use the Boost feature during icy or slippery road conditions.
4. Disconnect the trailer plug before testing a breakaway switch to prevent damage.

Hardware List:

• P3 Brake Control Unit.
• Mounting bracket.
• Wiring harness.
• #8 x 3/8" self-tapping screws.

Installation Instructions:

Mounting the Brake Control:

1. Traditional Bracket Mount:

   • Secure the bracket to a solid surface using the provided screws.
   • Attach the brake control unit and adjust to the desired angle.
   • Tighten screws securely.

2. Under Dash Pocket Mount:

   • Secure the small metal bracket with screws to a flat surface.
   • Attach the T-slot mount to the metal bracket and insert the brake control.

Wiring the Brake Control:

• Option 1: Use the included pigtail wiring harness for a generic installation.
• Option 2: Use an OEM-specific wiring harness compatible with the vehicle's tow package.
• Wire Functions:
  • Black: Positive power (+12V).
  • White: Vehicle ground.
  • Red: Cold side of brake pedal switch.
  • Blue: Trailer brakes output.

Setting Up the Control:

1. Connect the trailer to the vehicle.
2. Use the Menu/Options button to access the setup screen.
3. Select the brake type:
   • Electric: For electric brakes.
   • Hydraulic: For electric over hydraulic braking systems.
4. Adjust the power output to ensure effective braking without wheel lock-up.

Boost Feature:

• Provides enhanced braking sensitivity.
• Available in three levels:
  • B1: Light braking boost.
  • B2: Moderate braking boost.
  • B3: Aggressive braking boost.
• Recommended for heavier trailers or varying load conditions.

Reverse Mode:

• Cancel Boost and Hold features for 3 minutes by pressing and holding the Boost button for 5 seconds while holding the brake pedal.

Troubleshooting Guide:

Maintenance:

• Inspect connections and wiring regularly for damage or wear.
• Adjust trailer brakes after the first 200 miles of use and every 3,000 miles thereafter.
• Clean the brake control unit periodically to maintain optimal performance.

Warranty Information:

• Limited Lifetime Warranty:
  • Covers defects in materials and workmanship under normal use.
  • Excludes damage caused by misuse, improper installation, or external factors.
• Attention: For complete warranty instructions, please download the full installation PDF.

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.