Installation Instructions for Toyota RAV4

Part Numbers:

• 36588
• 90248
• 06172

Wiring Access Location:

• SUV1, SUV2

Tools Required:

• Ratchet
• Torque Wrench
• Safety Glasses
• Flat Head Screwdriver
• Sockets: 10mm, 12mm, 17mm, 19mm

Installation Time:

• Estimated: 20 minutes (for professional installers)

Step-by-Step Instructions:

1. Remove Plastic Appearance Panel:

   • On the driver side, use a flat head screwdriver and a 10mm socket to remove two (2) plastic rivets and one (1) flange nut from the panel.
   • Return the panel to the vehicle owner.

2. Remove Tie-Down Bracket:

   • Use a 17mm socket to remove two (2) bolts from the tie-down bracket on the driver side.
   • Return the tie-down bracket and bolts to the vehicle owner.

3. Lower the Exhaust:

   • Remove one (1) rubber isolator from the exhaust rod on the passenger side to lower the exhaust.

4. Remove Exhaust Rod:

   • Use a 12mm socket to remove two (2) bolts securing the exhaust rod near the trunk pan.
   • Return the exhaust rod to the vehicle owner.

5. Install Hitch:

   • Raise the hitch into position over the existing weldnuts.
   • Loosely install M12 bolts with conical washers into the weldnuts. On the driver side, sandwich the hitch bracket between the frame rail and the tie-down bracket.

6. Tighten Fasteners:

   • Use a torque wrench to tighten all M12 bolts to 76 lb-ft (103 N*m).

7. Reinstall Exhaust:

   • Reattach the exhaust rod at the rubber isolator.

Torque Specifications:

• M12 x 1.25 CL10.9 bolts: 76 lb-ft (103 N*m)

Hardware List:

• (5) M12 x 1.25 x 40mm CL10.9 Hex Bolts
• (5) 1/2" Conical Washers

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: 300 lb (136 kg)

Additional Notes:

• Drawbar Kit: 36051 (sold separately; must be used in the RISE position only)
• Fastener Kit: 36588F
• This product complies with V.E.S.C. Regulation V-5 and SAE J684 safety standards.

Installation Instructions for T-Connector Adapter

Part Numbers:

• 118412

Tools Required:

• Trim Panel Remover
• Phillips Head Screwdriver
• Drill with 3/32” Drill Bit
• 10mm and 12mm Wrench

Step-by-Step Instructions:

1. Prepare the Vehicle:

   • Open the rear hatch.
   • Temporarily remove the rear threshold plate, privacy screen, storage covers, and floor covering.
   • Partially remove the rear interior trim panels on both the driver and passenger sides of the vehicle.
   • Carefully remove several trim panel fasteners to free the panels. Set aside all items, taking care not to damage any parts.

2. Locate the Vehicle's Taillight Wiring Harness:

   • On both sides of the vehicle, locate the taillight wiring harness.
   • Identify the connector at the rear of the taillight assembly.
   • Carefully separate the connector, ensuring not to break the locking tabs. Clean all connector surfaces of dirt.

3. Install the Driver-Side T-Connector:

   • Attach the T-Connector ends containing the yellow and brown wires between the vehicle connectors on the driver’s side.
   • Ensure the connectors are fully inserted with locking tabs secured.

4. Route the Passenger-Side T-Connector:

   • Route the T-Connector containing the green wire below the threshold cover to the passenger side.
   • Repeat Step 3 using the T-Connector ends containing the green wire.

5. Mount the T-Connector Black Box:

   • On the driver’s side, find a flat surface in a location out of the way.
   • Mount the T-Connector’s black converter box using the provided double-sided tape.

6. Ground the White Wire:

   • Locate a suitable grounding point near the connector, such as the vehicle's frame or cross member.
   • Clean dirt and rustproofing from the area.
   • Drill a 3/32” hole and secure the white wire using the provided eyelet and screw.
   • Caution: Verify what is behind the surface before drilling to avoid damage or injury.

7. Connect the Power Wire:

   • Locate the red 12-gauge power wire from the T-Connector black box.
   • Attach the black 12-gauge wire provided in the kit.
   • Route the black wire through a grommet and along the exterior frame or follow the existing wiring along the thresholds to the engine compartment.

   Warning:

   • Avoid routing near hot pipes, heat shields, the fuel tank, or other areas that could pinch or break the wire.

8. Connect to the Vehicle Battery:

   • Disconnect the vehicle’s negative (-) battery cable.
   • Remove the fuse from the yellow fuse holder. Attach the ring terminal to the fuse holder wire and secure it to the positive (+) battery cable.
   • Connect the other end of the fuse holder to the black 12-gauge wire using the provided yellow butt connector.
   • Reconnect the negative (-) battery cable and install the 10-amp fuse into the fuse holder.

9. Secure the Wiring:

   • Use the provided cable ties to secure all loose wires.
   • Ensure the T-Connector harness is routed away from areas that could cut or pinch the wire.

10. Reassemble the Vehicle:

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

11. Test the Installation:

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

    Specifications:

    • Max. stop/turn light: 1 per side (2.1 amps)
    • Max. tail lights: (4.2 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 complete.

Manufacturer Notes:

• Read and follow all vehicle warnings and installation instructions carefully.
• Refer to the vehicle owner’s manual for additional information.