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:

1. Lower Exhaust:

   • Detach the exhaust from the rubber isolator to create space for installation.

2. 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.

3. 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.

4. 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.

5. 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.

6. 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.

7. Tighten Fasteners:

   • Torque all 1/2”-13 GR5 fasteners to 75 Lb.-Ft. (102 N*M) using a torque wrench.

8. 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:

1. 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.

2. 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.

3. 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.

4. 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.

5. 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.

6. 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.