Installation Instructions for Subaru Forester

Part Numbers:

• 75876
• 87654
• 44705

Wiring Access Location:

• SUV8

Tools Required:

• Metal File
• Wrenches: 11/16”, 10mm

Step-by-Step Instructions:

1. Lower Exhaust:

   • Disconnect the rubber exhaust hangers from the hanger brackets to lower the exhaust system.

2. Remove Heat Shield:

   • Remove four (4) heat shield screws from each frame rail and set aside.
   • Note: The heat shield will need to be trimmed for bolt clearance during reinstallation (refer to Figure 2).

3. Remove Plastic Plugs:

   • Remove four (4) plastic plugs from the existing holes in each frame rail. Retain only the rear access hole plug for reinstallation after the bolts are in place.

4. Install Fasteners:

   • Fishwire spacers and 7/16” carriage bolts through the access hole and down through the holes in both frame rails, ensuring the blocks span both sides of the hole and do not overlap (refer to Figures 1 and 3).

5. Reinstall Heat Shield:

   • Reinstall the trimmed heat shield using three (3) of the four (4) fasteners removed in Step 2. Leave out the rearmost fastener on the frame rail.

6. Install Hitch:

   • Raise the hitch into position carefully to avoid pushing the fasteners into the frame. Secure the hitch with conical washers and nuts.

7. Raise Exhaust:

   • Reattach the exhaust hangers disconnected in Step 1.

Hardware List:

• Qty (6): Carriage Bolt – 7/16-14 x 1.75 GR5
• Qty (6): Spacer (Square hole for 7/16” Carriage Bolt)
• Qty (6): Conical Washer – 7/16”
• Qty (6): Hex Nut – 7/16-14
• Qty (6): Pull Wire – 7/16”

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.
• Observe safety precautions when working beneath the vehicle and wear eye protection.
• Do not cut access or attachment holes with a torch.

Specifications:

• Hitch Type: Weight Distributing
  • Max Gross Trailer Weight: 4,000 lbs (1,816 kg)
  • Max Tongue Weight: 525 lbs (238 kg)
• Hitch Type: Weight Carrying (Ball Mount)
  • Max Gross Trailer Weight: 3,500 lbs (1,589 kg)
  • Max Tongue Weight: 525 lbs (238 kg)

Manufacturer Notes:

• Tighten all 7/16-14 GR5 fasteners to 50 lb-ft (68 N*m).
• 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 T-Connector Adapter for Subaru (Forester, Outback, XV Crosstrek)

Part Numbers:

• 118467

Tools Required:

• Trim Panel Remover
• Test Probe

Step-by-Step Instructions:

1. Prepare the Rear Cargo Area:

   • Open the vehicle’s rear tailgate.
   • Remove the cargo nets and cargo floor hatch to access the spare tire area.

2. Locate the Tow Plug Housing:

   • 2009-2013 Subaru Forester: Remove the driver’s side and center foam cargo trays to locate the tow plug housing under the driver’s side foam tray.
   • 2010-2019 Subaru Outback: Locate the tow plug housing behind the driver’s side trim panel. It is taped to the wire harness with blue tape.
   • 2014-Current Subaru Forester / XV Crosstrek: Locate the tow plug housing behind the driver’s side trim panel. It is taped to the wire harness with tape.
   • 2020-Current Subaru Outback: Temporarily remove the rear threshold plate. Locate the tow plug on the passenger side under the rear threshold plate. It is taped to the harness with tape.

3. Connect the T-Connector Harness:

   • Insert the T-Connector harness into the vehicle’s tow plug housing and lock it into place.
   • Ensure the connectors are fully inserted with the locking tabs engaged.

   Warning:

   • All connections must be complete for the T-Connector to function properly.
   • Test and verify the installation with a test light or trailer. For the initial test, reset the vehicle's electrical system by temporarily removing the key from the ignition.

4. Mount the Black Box:

   • On the driver’s side, mount the T-Connector black box using the provided double-sided tape.
   • Secure the remaining T-Connector harness with the provided cable ties, avoiding areas that could cut or pinch the wire.

   Note:

   • Store the 4-flat connector in the spare tire compartment when not in use.

   Warning:

   • Overloading circuits can cause fires. Do not exceed the lower of the towing manufacturer’s rating or the following specifications:
     • Max. stop/turn light: 1 per side (2.1 amps)
     • Max. tail lights: (5.6 amps)

Safety Notes:

• Always follow all warnings and instructions included with the product before beginning installation.
• Wear safety glasses and use all safety precautions during installation.

Manufacturer Notes:

• Refer to the vehicle owner’s manual and instruction sheet for additional details.

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.