Installation Instructions for Ford Explorer (2020-Current)

Part Numbers:

• 36787
• 06194
• CQT36787

Wiring Access Location:

• PC3

Tools Required:

• Ratchet
• Torque Wrench
• Safety Glasses
• Sockets: 7mm, 10mm, 21mm
• Tin Snips
• Flat Head Screwdriver
• Exhaust Removal Pliers
• Drill and 1/4" Drill Bit
• Plastic Rivet Gun
• Marker
• Tape Measure
• 6" Socket Extension

Installation Time:

• Estimated: 40 minutes (for professional installers)

Step-by-Step Instructions:

1. Remove Underbody Panel:

   • Using a 7mm socket and screwdriver, remove the screws and plastic push rivets securing the underbody panel between the mufflers.
   • Return the panel to the vehicle owner or trim to fit for reinstallation. Extensive trimming may be required.

2. Lower Exhaust:

   • Using a 10mm socket, remove the bolt securing the exhaust hanger on the outboard side of the frame rail.
   • Push the hanger up and outward to detach from the frame rail.
   • Use exhaust removal pliers to remove the rubber exhaust hanger near the rear differential. Support the exhaust to prevent damage.
   • Retain all fasteners for reinstallation.

3. Remove Heat Shields:

   • Remove nuts holding the heat shield with a 10mm socket.
   • Remove the screw attaching the heat shield to the wheel well liner using a 7mm socket.
   • Cut a 1.5" hole forward of the forward attachment in the heat shield to clear the middle hitch fastener.
   • Retain all fasteners for reinstallation.

4. Remove M16 Bumper Bolt:

   • Using a 21mm socket, remove the bumper bolt from the bottom of the frame rail. Retain the bolt for reinstallation.

5. Remove Rear Fascia Fasteners:

   • Remove the plastic push rivets from the lower edge of the rear fascia. Retain for reinstallation.

6. Remove Kick Sensor (if applicable):

   • Using a 1/4" drill bit, remove the four (4) rivets holding the kick sensor in place.

7. Trim Fascia:

   • Move the kick sensor aside to avoid damage during trimming.
   • Locate the center of the fascia and trim per the dimensions provided in Figure 3. Dimensions are approximate.

8. Install Hitch:

   • Use the provided pull wires to install carriage bolts and spacers through the forward attachment points in the vehicle frame. Leave pull wires attached.
   • Ensure weldnuts are free from rust and debris.
   • Raise the hitch into position, aligning the bracket holes with the frame rail weldnuts. Guide the pull wire ends through the hitch bracket holes and loosely reinstall the M16 bumper bolts removed earlier.
   • Remove pull wires and attach conical washers (teeth side toward hitch) and hex nuts. Tighten all fasteners.

9. Tighten Fasteners:

   • Tighten M16 fasteners to 146 ft-lb (198 N*m).
   • Tighten 1/2" fasteners to 75 ft-lb (102 N*m).

10. Reinstall Modified Heat Shields:

    • Reinstall the modified heat shields over the hitch bracket using all previously removed fasteners.

11. Reinstall Exhaust:

    • Reinstall the kick sensor, if applicable.
    • Raise the exhaust back into position and secure all hangers and fascia fasteners.

Torque Specifications:

• M16 bolts: 146 ft-lb (198 N*m)
• 1/2"-13 GR5 bolts: 75 ft-lb (102 N*m)

Hardware List:

• (2) Carriage Bolts, 1/2"-13 x 1.25" GR5
• (2) Spacers, 0.250" x 1" x 3"
• (2) Conical Washers, 1/2"
• (2) Hex Nuts, 1/2"-13
• (2) Pull Wires, 1/2"-13
• (4) Plastic Rivets

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 trunk pan or other body panels to prevent water or 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:

• Max Gross Trailer Weight: 3,500 lb (1,589 kg)
• Max Tongue Weight: 350 lb (159 kg)

Additional Notes:

• Authorized Drawbar Kit: 36071 (sold separately; must be used in the RISE position only).
• Fastener Kit: 36787F.
• This product complies with V.E.S.C. Regulation V-5 and SAE J684 safety standards.

Installation Instructions for T-One® T-Connector for Lincoln Aviator

Part Numbers:

• 118817

Tools Required:

• Trim Panel Remover
• 10mm Socket & Ratchet or Wrench
• Drill (3/32” Drill Bit)
• 1/4” Socket
• Wire Crimpers
• Wire Cutters
• Phillips Head Screwdriver
• Test Probe

Step-by-Step Instructions:

1. Open the Rear Hatch:

   • Temporarily remove the rear threshold plate, privacy screen, storage covers, and floor covering.
   • Open the rear door and fold the rear seat forward.

2. Remove Interior Trim Panels:

   • Partially remove the rear interior trim panels on both the driver and passenger sides.
   • Remove the necessary trim panel fasteners to access the taillight wiring harness.
   • Set aside all removed items carefully to avoid damage.

3. Locate the Vehicle’s Taillight Wiring Harness:

   • On both sides of the vehicle, locate the vehicle’s taillight wiring harness.
   • Disconnect the connectors carefully, ensuring not to break the locking tabs.
   • Ensure all connector surfaces are clean and free of dirt.

4. Connect the Driver-Side T-Connector:

   • Insert the T-One® Connector end with the yellow wire between the vehicle’s wiring connectors.
   • Lock the connectors securely into place.

5. Route the Passenger-Side T-Connector:

   • Route the connector containing the green wire down the threshold to the passenger side of the vehicle.
   • Insert the T-One® Connector end with the green wire between the vehicle’s wiring connectors.

6. Ground the White Wire:

   • Locate a suitable grounding point near the connector, such as the vehicle’s frame or crossmember.
   • Clean dirt and rustproofing from the grounding area.
   • Drill a 3/32” hole and secure the white wire using the provided eyelet and screw.

   Caution: Verify the area behind any surface before drilling to avoid damage or injury.

7. Route the Power Wire:

   • Locate the black 12-gauge power wire from the T-One® T-Connector box on the driver’s side.
   • Attach the provided black wire and route it along the vehicle’s exterior frame to the engine compartment, avoiding areas that may pinch, cut, or melt the wire.

8. Connect to the Vehicle Battery:

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

   Warning: Follow all warnings printed on the vehicle’s battery.

9. Reconnect the Battery and Test:

   • Reconnect the Negative (-) battery cable.
   • 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.

10. Mount the T-One® Black Box:

    • Locate a flat surface in an out-of-the-way location and mount the black box module using the provided double-sided tape.

11. Secure the Harness:

    • Use the provided cable ties to secure the remaining T-One® T-Connector harness, avoiding areas where it could pinch, cut, or melt.

12. Reassemble the Vehicle:

    • Replace all panels, clips, and floor coverings removed during installation.

13. Store the 4-Flat Connector:

    • Store the 4-flat connector in the rear cargo area when not in use.
    • When in use, pull the 4-flat connector through the door and close carefully, avoiding pinching the harness in the door latch.

Safety Notes:

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