Installation Instructions for Dodge Charger, Chrysler 300, Dodge Challenger (Excluding Quad Exhaust Models), and Dodge Magnum

Part Numbers:

• 36548
• 90243
• 06946

Wiring Access Location:

• PC3

Tools Required:

• Sockets: 8mm, 13mm, 15mm, 18mm, 3/4"
• Torque Wrench
• Safety Glasses
• Flat Head Screwdriver
• Plastic Trim Tools
• Ratchet
• Extension
• Universal Joint

Installation Time:

• 30 minutes: For vehicles with exhausts that separate at the rear.
• 50 minutes: For vehicles with welded exhausts and riveted exhaust tips (fascia removal required).

Step-by-Step Instructions:

Pre-2011 Models:

1. Lower Exhaust:

   • Remove two (2) exhaust hanger brackets per side using a 13mm socket.
   • Apply lubricant or soapy water to ease the removal of the metal hanger rod from the rubber isolator.

2. Prepare Weldnuts:

   • Run the M12 bolt into the existing weldnuts to clean out any debris.

3. Fishwire Hardware:

   • Fishwire 1/2" carriage bolts and spacers through the access holes on the driver and passenger side frame rails.
   • Pull the hardware through the existing holes (two on the passenger side, one on the driver side).

4. Position Hitch:

   • Slide the hitch over the mufflers and align it with the frame.
   • Loosely install the M12 bolt and conical washer (teeth side facing the hitch) into the existing weldnut.

5. Secure Fasteners:

   • Install the 1/2" conical tooth washers (teeth side facing the hitch) and 1/2" hex nuts.

6. Torque Fasteners:

   • Tighten all 1/2" fasteners to 75 ft-lb (102 N*m).
   • Tighten the M12 bolt to 68 ft-lb (92 N*m).

7. Reinstall Exhaust:

   • Reattach the exhaust hangers.

2011 and Newer Models:

1. Remove Plastic Appearance Panels:

   • For Chrysler 300/300C, remove the plastic panels covering the trunk pan. Return the panels to the vehicle owner.

2. Lower Exhaust:

   • Remove two (2) exhaust hanger brackets per side using a 13mm socket.
   • Push the muffler upward and outward to access the frame rail.

3. Remove Muffler:

   • V8 Models: Remove and save the two (2) assembly bolts and springs from the flange. Carefully remove the muffler.
   • V6 Models: Remove and save the band clamp, separate the exhaust pipes, and remove the muffler.

4. Prepare Weldnuts:

   • Run the M12 bolt into the existing weldnuts to clean out any debris.

5. Fishwire Hardware:

   • Fishwire 1/2" carriage bolts and spacers through the access holes on the driver and passenger side frame rails.
   • Pull the hardware through the existing holes (two on the passenger side, one on the driver side).

6. Install Passenger-Side Bracket:

   • Position the bracket over the passenger muffler.
   • Support the bracket and loosely install the M12 bolt and conical tooth washer through the bracket and into the frame rail.
   • Push the passenger muffler upward and outward for clearance, and install the 1/2" conical washers and hex nuts.

7. Torque Fasteners:

   • Tighten all 1/2" fasteners to 75 ft-lb (102 N*m).
   • Tighten the M12 bolt to 68 ft-lb (92 N*m).

8. Reinstall Components:

   • Reattach the exhaust hangers and reinstall wiring and fascia.

Torque Specifications:

• 1/2"-13 GR5 bolts: 75 ft-lb (102 N*m)
• M12 CL10.9 bolts: 68 ft-lb (92 N*m)

Hardware List:

• (3) Carriage Bolts, 1/2"-13 x 1.50" GR5
• (3) Spacer Blocks, 1" x 3"
• (3) Hex Nuts, 1/2"
• (4) Conical Washers, 1/2"
• (1) Hex Bolt, M12 x 1.75 x 40mm CL10.9
• (3) Fish Wires, 1/2"-13

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 a vehicle and wear eye protection.
• Do not cut access or attachment holes with a torch.

Specifications:

• Max Gross Trailer Weight: 3,500 lb (1,587 kg)
• Max Tongue Weight: 300 lb (136 kg)

Additional Notes:

• Authorized Drawbar Kit: 36061 (sold separately; must be used in the RISE position only)
• Fastener Kit: 36548F
• This product complies with V.E.S.C. Regulation V-5 and SAE J684 safety standards.

Installation Instructions for T-Connector Adapter

Part Numbers:

• 118404

Tools Required:

• Drill with a 3/32” drill bit
• Phillips head screwdriver

Step-by-Step Instructions:

1. Locate the Vehicle Wiring:

   • Open the trunk and remove the plastic wing nuts located behind each taillight.
   • Pull back the carpet to expose the vehicle's taillight wiring.

2. Driver’s Side Connection:

   • Disconnect the vehicle's wire harness from the driver’s side taillight socket by sliding the red locking tab to the unlocked position.
   • Plug the T-Connector with the yellow wire between the vehicle's wiring harness and taillight socket.
   • Ensure all connectors are fully inserted and the locking tabs are secure.

3. Passenger’s Side Connection:

   • Route the T-Connector with the green wire along the threshold to the passenger’s side of the vehicle.
   • Push the wiring between the vehicle body and the carpet.
   • Repeat the connection process for the passenger’s side using the T-Connector with the green wire.

4. Ground the White Wire:

   • Locate a suitable grounding point near the adapter, such as the vehicle frame or crossmember.
   • Clean the grounding area to remove dirt and rustproofing.
   • Drill a 3/32” hole and 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 exposed surfaces.

5. Reassembly:

   • Reinstall the carpet, plastic wing nuts, and any other clips or panels removed during installation.
   • Be careful not to cut or pinch the wires during reassembly.

6. Test the Installation:

   • Verify the T-Connector functionality using a test light or trailer.

   Specifications:

   • Max. stop/turn light: 1 per side (7.5 amps)
   • Max. tail lights: (7.5 amps)

Safety Notes:

• Do not exceed the towing manufacturer’s rating or the unit specifications.
• Overloading circuits can cause fires.
• Ensure all connections are secure and properly tested.

Manufacturer Notes:

• Read and follow all warnings and instructions provided.
• Refer to the vehicle owner’s manual for additional guidance.