Installation Instructions for Volvo XC40 (2019-Present)

Part Numbers:

• 76245
• 84245
• CQT76245

Tools Required:

• Safety Glasses
• Ratchet
• Torque Wrench
• Sockets: 8mm, 15mm
• 6" Socket Extension
• T25 Torx Bit
• Plastic Trim Tools
• Utility Knife
• Marker
• Tape Measure
• Silicone Sealant
• Gloves

Weight Capacities:

• Weight Carrying:
  • Max Gross Trailer Weight: 4,000 lbs (1,816 kg)
  • Max Tongue Weight: 600 lbs (272 kg)
• Weight Distributing:
  • Not Applicable

Installation Time:

• Estimated: 70 minutes

Step-by-Step Instructions:

1. Remove Lower Fascia:

   • Using a T25 Torx bit, remove (5) screws holding the wheel well liner to the fascia on both sides.
   • Use an 8mm socket to remove (4) bolts from the bottom edge of the fascia (2 per side). Do not remove the (4) Torx screws from the bottom edge of the fascia.
   • Use plastic trim tools to detach the lower fascia from the upper fascia starting at the outer edges near the wheel wells. Gently pull rearward to release the clips.
   • Disconnect the backup sensor wiring harness at (4) locations and unplug the middle wiring plug from the hands-free liftgate housing.
   • Remove (2) lights from the fascia, unclip the wiring harness as needed, and set the fascia aside carefully.

2. Remove Bumper Beam:

   • Use a 15mm socket to remove (6) M10 flange nuts from the bumper beam. Set the bumper beam aside.

3. Prepare Hitch Mounting Area:

   • Using a utility knife, remove excess caulk from the end panel near the hitch bracket mounting surface to ensure the bracket sits flat.

4. Apply Sealant:

   • Apply silicone sealant to the hitch bracket mounting surfaces on both sides.

5. Install Hitch and Bumper Beam:

   • Raise the hitch and bumper beam into position, aligning the holes with the studs on the end panel.
   • Loosely reinstall the (6) M10 flange nuts onto the studs.

6. Tighten Fasteners:

   • Use a torque wrench to tighten all M10 flange nuts to 38 lb-ft (52 N·m).

7. Trim Lower Fascia:

   • Using a tape measure, marker, and utility knife, cut a notch in the lower fascia approximately 3.5 inches wide and 3.5 inches tall.

8. Reinstall Lower Fascia:

   • Align the tabs in the lower fascia with the upper fascia and reinstall it.
   • Secure the original fasteners and reconnect all wiring disconnected in Step 1.

Safety Notes:

• Regularly inspect the hitch and all fasteners for secure attachment.
• Plug all holes in the trunk pan or body panels if the hitch is removed to prevent water or exhaust entry.
• Replace any damaged hitch or ball immediately.
• Always wear safety glasses and observe safety precautions when working under the vehicle.
• Do not cut access or attachment holes with a torch.

Specifications:

• Hitch Type: Class III
• Compliance: This product meets safety specifications and requirements as per V.E.S.C. Regulation V-5 and SAE J684.

Note: Always adhere to the vehicle manufacturer's weight rating or the hitch’s maximum load rating, whichever is lower.

Installation Instructions for T-One® T-Connector for Volvo XC40

Part Numbers:

• 118792

Tools Required:

• Trim Panel Remover
• 10mm Socket & Ratchet or 10mm Wrench
• 8mm Socket & Ratchet or 8mm Wrench
• Drill (3/32” Drill Bit)
• Wire Crimpers
• Wire Cutters
• Phillips Head Screwdriver
• Test Probe

Step-by-Step Instructions:

1. Open the Rear Hatch:

   • Unlatch and remove the rear floor section.
   • Remove 10 bolts from the side panel supports and threshold using an 8mm socket and set them aside.
   • Pull back the side panels to access the taillight wiring harness.

2. Connect the Driver-Side T-Connector:

   • Insert the T-One® Connector end with the yellow wire between the vehicle wiring connectors and lock into place.
   • Ensure the connectors are fully inserted, and the locking tabs are securely engaged.

3. Mount the T-One® Black Box:

   • Mount the T-One® Connector black box on the driver’s side using the provided double-sided tape.
   • Secure the remaining harness with the provided cable ties to prevent damage or rattling, avoiding any areas that could pinch or cut the wires.

4. Ground the White Wire:

   • Locate a suitable grounding point near the connector, such as an existing ground stud, or drill a 3/32” hole.
   • Clean the area of dirt or rustproofing before securing the white wire with the provided eyelet and screw.

   Caution: Verify what is behind any surface before drilling to avoid damage or injury.

5. Route the Passenger-Side T-Connector:

   • Route the connector containing the green wire down the threshold to the passenger side of the vehicle.

6. Connect the Passenger-Side T-Connector:

   • Insert the T-One® Connector end with the green wire between the passenger-side wiring connectors and lock into place.
   • Ensure the connectors are fully inserted with locking tabs securely engaged.

7. Route the Power Wire:

   • Locate the black 12-gauge power wire from the T-One® Connector box.
   • Attach the provided black wire and route it along the vehicle’s exterior frame or existing wiring to the engine compartment, avoiding hot pipes, heat shields, or other areas that could pinch or damage the wire.

8. Connect to the Vehicle Battery:

   • Disconnect the vehicle’s Negative (-) battery cable.
   • Remove the fuse from the yellow fuse holder and attach the ring terminal to the Positive (+) battery cable.
   • Connect the other end of the fuse holder to the black wire using the provided yellow butt connector.

9. Secure the Harness:

   • Secure the remaining T-One® Connector harness with the provided cable ties to avoid damage or rattling.

10. Reconnect the Battery and Test:

    • Reconnect the Negative (-) battery cable and insert the 15-amp fuse into the fuse holder.
    • Test the installation using a test light or trailer.
    • Reset the vehicle’s electrical system by temporarily removing the key from the ignition.

11. Reassemble the Vehicle:

    • Reinstall the plastic trim panels, threshold, storage covers, and floor covering.
    • Ensure no wires are pinched or damaged during reassembly.

12. Store the 4-Flat Connector:

    • Store the 4-flat connector in the rear cargo area when not in use.

Safety Notes:

• Overloading circuits can cause fires. Do not exceed stated product ratings.
• Always wear safety glasses and follow safety precautions during installation.

Manufacturer Notes:

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