Product Details
- Brand: Reese
- Model: 77122 118398 3593 63820
- SKU: 77122 118398 3593 63820
- Includes: Class 1 Trailer Tow Hitch, T-One T-Connector Custom Harness, Trailer Tow Hitch Ball Mount, Trailer Tow Hitch Ball
Compatibility Chart
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Reese Trailer Tow Hitch For 05-10 Chevy Cobalt Except SS 05-06 Pursuit Canada Only Complete Package w/ Wiring Draw Bar and 2" Ball Install Notes
Installation Instructions for Chevrolet Cobalt, Pontiac G5, and Pontiac Pursuit (Canada Only)
Part Numbers:
- 77122
- 24745
- 60808
Wiring Access Location:
- PC1, PC2
Tools Required:
- Drill
- Pull Wire (Provided)
- Wrenches: 3/4"
- Drill Bits: 1/2"
Specifications:
- Max Gross Trailer Weight: 2,000 lb. (908 kg)
- Max Tongue Weight: 200 lb. (90.8 kg)
- Note: Do not exceed towing vehicle ratings.
Step-by-Step Instructions:
-
Lower Exhaust:
- Detach the exhaust from the rubber isolator to create space for installation.
-
Drill Frame Rail and Reinforcement Bracket:
- Locate the 3/8” hole in the frame reinforcement bracket welded to the frame rail.
- Center punch and drill a 1/2” hole in the frame rail, enlarging the 3/8” hole in the frame reinforcement bracket to 1/2”. Repeat on both sides.
-
Fishwire Carriage Bolt and Spacer:
- Use the fishwire to guide the spacer and carriage bolt through the access slot in the frame rail and down through the drilled hole. Create a kink in the pull wire for tight areas (as shown in Figure 3). Repeat for both sides.
-
Position Hitch:
- Raise the hitch into position, taking care not to push the carriage bolts back into the frame.
- Secure the hitch using conical washers and nuts.
-
Drill Holes in Impact Bar:
- Ensure the hitch is centered on the vehicle.
- Using the hitch as a template, drill two (2) 1/2” holes into the vehicle’s impact bar.
-
Install Carriage Bolts in Impact Bar:
- On the driver’s side, install the carriage bolt and spacer from the open face of the impact bar and down through the hole drilled in Step 5. Secure with a lock washer and nut.
- On the passenger’s side, fishwire the carriage bolt and spacer through the end of the impact bar and down through the hole drilled in Step 5. Secure with a lock washer and nut.
-
Tighten Fasteners:
- Torque all 1/2”-13 GR5 fasteners to 75 Lb.-Ft. (102 N*M) using a torque wrench.
-
Reattach Exhaust:
- Raise the exhaust back into position and reattach it to the rubber isolator.
Hardware List:
- (4) Carriage Bolts: 1/2”-13 x 1.75”
- (4) Spacers: 1/4” x 1” x 3”
- (2) Conical Washers: 1/2”
- (4) Hex Nuts: 1/2”-13
- (2) Lock Washers: 1/2”
Safety Notes:
- Regularly inspect all fasteners and the hitch ball to ensure proper tightening.
- Plug any holes in the trunk pan or body panels if the hitch is removed to prevent water and exhaust fumes from entering.
- Replace any damaged hitch or ball immediately.
- Always wear safety glasses when working beneath the vehicle.
- Do not use a torch to cut access or attachment holes.
Drawbar:
- Drawbar Kit: 3593
- Important: The drawbar must be used in the rise position only.
Compliance:
- This product complies with SAE J684, V.E.S.C. Regulation V-5, and the safety requirements of the State of New York.
Additional Notes:
- Does not fit Chevrolet Cobalt SS Coupe, Pontiac Pursuit GT, or Pontiac G5 GT models.
Installation Instructions for T-Connector Adapter
Part Numbers:
- 118398
Tools Required:
- 9/32" Socket
- Philips Head Screwdriver (if needed)
- Drill with 3/32" Drill Bit (if needed)
Step-by-Step Instructions:
-
Remove Rear Taillight Assemblies:
- Open the trunk and locate the plastic wing nuts behind the taillights on both sides (1 per side). Remove them.
- Pull back the carpet on both sides to expose and remove the second set of plastic wing nuts (1 per side).
- Locate and remove the remaining taillight screws outside the vehicle near the trunk weather seal (2 screws per side). Use a 9/32" socket.
- Carefully pull the taillights away from the vehicle, ensuring the alignment pins are not damaged.
-
Connect T-Connector on Driver’s Side:
- Disconnect the vehicle’s wiring harness from the driver’s side taillight socket.
- Plug the T-Connector end with the yellow wire between the taillight socket and the vehicle wiring harness.
-
Route the T-Connector Harness:
- Route the T-Connector end with the green wire and the 4-flat connector down through the opening between the vehicle’s bumper and body.
- Route the green wire to the passenger side and the 4-flat connector under the bumper.
- Bring the green wire up through the opening on the passenger side.
- Avoid areas with hot pipes, heat shields, the fuel tank, or other points that may pinch or damage the wire.
- Repeat step 2 for the passenger side using the T-Connector end with the green wire.
-
Ground the White Wire:
- Locate a suitable grounding point near the connector (e.g., an existing ground stud). If necessary, drill a 3/32" hole.
- 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.
-
Reinstall Taillight Assemblies:
- Position the vehicle wiring harness between the taillight housing and the vehicle body.
- Reinstall the screws, plastic wing nuts, carpet, and other components removed during installation. Ensure wires are not pinched or cut.
- Secure the remaining T-Connector harness under the bumper using the provided cable ties.
-
Test the Installation:
- Test the T-Connector with a test light or trailer to verify proper functionality.
- All connections must be complete for the T-Connector to work correctly.
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. Test the installation thoroughly to ensure proper functionality.
Manufacturer Notes:
- Follow all warnings and installation instructions provided.
- Refer to the vehicle owner’s manual for additional information.