Installation Instructions for GMC & Chevrolet 2500HD/3500/3500HD Sierra & Silverado Trucks

Part Numbers:

• 41944
• 96944

Wiring Access Location:

• PU3

Tools Required:

• Wrenches: 13/16", 7/8", 18mm, 21mm, 22mm
• Drill Bits: None

Step-by-Step Instructions:

1. Remove Existing Bolts:

   • Remove M14 bolts from the bottom of each truck frame rail’s bumper bracket.
   • Return these bolts to the vehicle owner.

2. Position Hitch:

   • Lift the hitch into position, aligning the rearmost slots on the hitch under the existing weldnuts in the truck frame.

3. Install Rear M14 Bolts:

   • Install the new M14 bolts through lock washers, blocks, and the hitch into the weldnuts in the truck frame.

4. Remove Side Nuts and Bolt Plates:

   • Remove M12 nuts and bolt plates from the sides of the frame.
   • Retain these for reinstallation later.

5. Adjust Bumper Brace (2001–2007 Models):

   • Loosen the nuts at the bumper end of the bumper brace, allowing it to swing away.

6. Install Attachment Bars:

   • Place attachment bars as shown in the instructions and loosely bolt them to the hitch.
   • For 2001–2007 models, swing the brace back and secure it as shown.

7. Install Remaining Fasteners:

   • Install remaining fasteners through the existing large holes in the truck frame as shown.
   • Use thinner blocks (1/4" x 3") under the hitch and orient the holes in the blocks to ensure they lay flat against the hitch when tightened.

8. Tighten Fasteners:

   • Torque all M14 x 1.5 (fine-thread) fasteners to 148 lb-ft (201 N*m).
   • Torque all M12 fasteners to 92 lb-ft (125 N*m).
   • Torque all M14 x 2.0 (course-thread) fasteners to 148 lb-ft (201 N*m).

Torque Specifications:

• M14 x 1.5 (fine-thread): 148 lb-ft (201 N*m)
• M14 x 2.0 (course-thread): 148 lb-ft (201 N*m)
• M12 fasteners: 92 lb-ft (125 N*m)

Hardware List:

• (2) Hex Bolts, M14 x 1.5 x 45mm CL10.9
• (2) Hex Bolts, M14 x 2.0 x 60mm CL10.9
• (6) Hex Bolts, M12 x 1.75 x 45mm CL10.9
• (2) Spacer Blocks, 3/8" x 1-1/2" x 3"
• (2) Spacer Blocks, 1/4" x 1-1/2" x 3" (offset hole)
• (2) Spacer Blocks, 3/8" x 1-1/2" x 2"
• (10) Conical Washers, 1/2"
• (2) Lock Washers, 1/2"
• (2) Lock Washers, 9/16"
• (6) Nuts, M12 x 1.75 CL10
• (2) Nuts, M14 x 1.5 CL10.9
• (2) Nuts, M14 x 2.0 CL8

Safety Notes:

• Frequently check the hitch to ensure all fasteners and the ball are securely tightened.
• 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.
• Always wear eye protection and observe safety precautions when working beneath a vehicle.
• Do not cut access or attachment holes with a torch.

Specifications:

• Weight Carrying (Ball Mount):
  • Max Gross Trailer Weight: 13,000 lb (5,902 kg)
  • Max Tongue Weight: 1,950 lb (886 kg)
• Weight Distributing:
  • Max Gross Trailer Weight: 16,000 lb (7,264 kg)
  • Max Tongue Weight: 1,600 lb (726 kg)

Additional Notes:

• Complies with V.E.S.C. Regulation V-5 and SAE J684 safety standards.
• Ensure proper alignment and torque specifications are followed to maintain safety and performance.

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