Installation Instructions for Toyota Highlander and Highlander Hybrid (2020-Present)

Part Numbers:

• 75992
• 44763
• CQT75992

Tools Required:

• Ratchet
• Torque Wrench
• Safety Glasses
• Sockets: 17mm, 19mm

Wiring Access Location:

• SUV3, SUV4

Step-by-Step Instructions:

1. Prepare Frame Rails:

   • Remove any rubber plugs from the bottom of the frame rails to expose the weldnuts.
   • Clean the threads of the weldnuts with a wire brush to remove any debris or corrosion.

2. Position the Hitch:

   • Raise the hitch into position under the vehicle, aligning the slots on the hitch with the weldnuts in the vehicle frame.

3. Install Fasteners:

   • Secure the hitch using six (6) M12 x 1.25 x 40mm CL10.9 hex bolts and six (6) 1/2" conical toothed washers.
   • Ensure the toothed side of the washers faces the hitch.

4. Tighten Fasteners:

   • Use a torque wrench to tighten all M12 fasteners to 79 lb-ft (107 Nm).

5. Verify Installation:

   • Double-check that all bolts are securely tightened, and the hitch is properly aligned.

Hardware List:

• (6) M12 x 1.25 x 40mm CL10.9 Bolts
• (6) 1/2" Conical Toothed Washers

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.
• Always follow 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 (Ball Mount): Max Trailer Weight 5,000 lbs (2,268 kg), Max Tongue Weight 500 lbs (227 kg).
  • Weight Distributing: Max Trailer Weight 6,000 lbs (2,721 kg), Max Tongue Weight 600 lbs (272 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.

Additional Notes:

• Installation time is approximately 30 minutes for a professional installer.
• If you encounter difficulty installing, consult a professional or contact customer support.

Installation Instructions for T-Connector Adapter for Ford Edge

Part Numbers:

• 118515

Tools Required:

• Trim Panel Remover
• 10mm Socket & Ratchet or 10mm Wrench
• Drill (3/32” Drill Bit)
• Test Probe
• Wire Crimpers
• Wire Cutters

Step-by-Step Instructions:

1. Open the Rear Tailgate:

   • Remove cargo nets and the cargo floor hatch to access the spare tire area.
   • Remove both taillight housing assemblies by unscrewing the two bolts on each light.
   • Carefully pry the taillight housing assembly away from the vehicle to avoid breaking the alignment tabs.

2. Disconnect the Wiring Harness:

   • Locate the wiring harness in the taillight pocket on both the driver’s and passenger’s sides.
   • Disconnect the harness connectors.

3. Route the T-Connector Wiring:

   • On both sides, slit the grommet to allow the T-Connector wiring to pass through.
   • Route the T-Connector wiring through the interior trim panels and along the threshold plate.
   • Pass the T-Connector wiring containing the green wire to the passenger side and through the grommet hole.

4. Connect the T-Connector:

   • On the driver’s side, insert the T-Connector end with the yellow wire between the mating plugs on the taillight socket and vehicle wiring harness.
   • Repeat the process on the passenger side using the T-Connector end with the green wire.

5. Ground the White Wire:

   • Locate a suitable grounding point near the connector, such as the vehicle’s frame or cross member.
   • Clean the area and drill a 3/32” hole.
   • Secure the white wire using the provided eyelet and screw.

   Caution:

   • Verify what is behind any surface before drilling to avoid damage or injury.
   • Do not drill into the vehicle floor or any exposed surfaces.

6. Connect the Black Power Wire:

   • Route the black 12-gauge wire along the frame rail, avoiding hot pipes, heat shields, and the fuel tank.
   • Connect the black wire and the two black wires from the T-Connector’s grey 12-pin connector using the supplied yellow butt connector.

7. Connect to the Vehicle Battery:

   • Disconnect the negative battery cable.
   • Attach the ring terminal from the fuse holder to the positive battery cable and secure it.
   • Insert the 15-amp fuse into the fuse holder.

   Warning:

   • All connections must be complete for the T-Connector to function properly.
   • Test and verify the installation with a test light or trailer.

8. Mount the Black Box:

   • Mount the T-Connector’s black box module to a flat surface inside the vehicle, using the provided double-sided tape.
   • Secure the T-Connector harness with the provided cable ties, ensuring wires are not pinched, cut, or melted.

   Note:

   • The black box module must be mounted only inside the vehicle to prevent water or liquid exposure.

9. Reassemble the Vehicle:

   • Reinstall the taillight housing assemblies and all interior trim panels, ensuring no wires are pinched or damaged.

Specifications:

• Max. stop/turn light: 4.2 amps
• Max. tail lights: 7.5 amps

Safety Notes:

• Overloading circuits can cause fires. Do not exceed the towing manufacturer’s rating or the unit specifications.
• Always follow installation instructions and safety precautions.

Manufacturer Notes:

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

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.