Installation Instructions for Saturn Aura and Chevrolet Malibu

Part Numbers:

• 36479
• 90194
• 06658
• 36327 (U-Haul)

Wiring Access Location:

• PC1, PC2

Tools Required:

• Wrenches: 11/16", 3/4"
• Drill Bits: 1/2", 3/8"
• Pull Wires (Provided)

Step-by-Step Instructions:

For Vehicles Without Existing Holes:

1. Position Hitch:

   • Raise the hitch into position and align it over the bumper attachment bolt.
   • Ensure the bracket sits flat against the frame rail.

2. Drill Holes:

   • Mark and center punch the hole locations using the hitch as a template.
   • Drill two 3/8" holes through the end panel. Remove burrs.

3. Install Hardware:

   • Tape spacers into position behind the end panel.
   • Feed pull wires through the spacers and attach carriage bolts.
   • Pull reinforcement plates and carriage bolts into position.

4. Secure Hitch:

   • Install conical washers and nuts onto the carriage bolts.
   • Tighten all fasteners according to torque specifications.

For Vehicles With Existing Holes:

1. Prepare Hardware:

   • Tape spacers into position.
   • Feed pull wires through the spacers, attach carriage bolts, and pull into place.

2. Install Hitch:

   • Raise the hitch into position.
   • Secure with conical washers and nuts.

3. Drill Frame Holes:

   • Drill two 1/2" holes through the frame rail using the hitch as a guide.

4. Install Frame Hardware:

   • Feed pull wires through the hitch bracket and frame rail.
   • Attach spacers and carriage bolts to the pull wires and pull into position.
   • Secure with lock washers and nuts.

5. Torque Fasteners:

   • Tighten all 3/8"-16 GR5 fasteners to 30 ft-lbs (47 N*m).
   • Tighten all 1/2"-13 GR5 fasteners to 75 ft-lbs (102 N*m).

Hardware List:

• (2) Carriage Bolt 3/8"-16 x 1.50" GR5
• (2) Carriage Bolt 1/2"-13 x 1.75" GR5
• (2) Spacer 1/4" x 1" x 2" (Square Hole)
• (2) Spacer 1/4" x 1" x 3" (Square Hole)
• (2) Conical Washer 3/8"
• (2) Conical Washer 1/2"
• (2) Lock Washer 1/2"
• (2) Nut 3/8"-16
• (2) Nut 1/2"-13

Safety Notes:

• Regularly 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 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:

• Weight Carrying Capacity: 3,500 lbs (1,589 kg) trailer weight, 300 lbs (136 kg) tongue weight.
• Weight Distributing Capacity: Not applicable.
• Drawbar must be used in the rise position only.
• Product complies with V.E.S.C. Regulation V-5 and SAE J684.

Additional Notes:

• Installation time for professional installers is approximately 30 minutes.
• For more detailed instructions, refer to the QR code or manual provided.

Installation Instructions for Modulite® HD Protector Vehicle Wiring

Part Number:

• 119148

Tools Required:

• Phillips Head #2 Screwdriver
• Wire Cutters
• Wire Strippers/Wire Crimpers
• Tester or Volt Meter
• Socket & Ratchet Set
• Drill with 3/32” Drill Bit
• Double-Sided Tape

Step-by-Step Instructions:

Tow Vehicle Inputs - Determination:

1. Disconnect and isolate the vehicle's negative battery terminal.
   • Warning: Read and follow all warnings and instructions on the tow vehicle's battery.
2. Splice the tow harness input wires to the vehicle as determined.
   • Caution: Use appropriate gauge wire splices. Blue taps are for 16-18 gauge wires only.

Harness Installation:

1. Determine the mounting location of the module and secure it using the double-sided tape provided.
   • Warning: Mount the module with the epoxy side pointed towards the ground to prevent water buildup.
2. Locate a suitable grounding point near the module, such as an existing ground stud, or drill a 3/32” hole to secure the white wire using the provided eyelet and screw.
   • Caution: Verify what is behind any surface before drilling to avoid damage or personal injury.
3. Route the power wire to the vehicle’s positive battery terminal. Use the provided fuse holder, butt connector, and ring terminal to connect to the battery.
   • Do not insert the 15 amp fuse yet.
   • Caution: Ensure the module is connected to a constant power source and avoid routing the wire near hot pipes, heat shields, fuel tanks, or pinch points.

Completion:

1. Secure the harness with cable ties provided to prevent damage or rattling.
2. Reconnect the vehicle's negative battery cable.
3. Insert the 15 amp fuse into the fuse holder and close the cap.
4. Test the installation using a test light or trailer. Check each function independently and in combination.

Hardware List:

• 8 × Cable Ties, 8.5”
• 1 × 15 AMP Fuse
• 2 × Ring Terminals
• 1 × Fuse Holder
• 2 × Yellow Butt Connectors
• 1 × Self-Tapping Screw
• 4 × Blue Taps
• 1 × Spade Terminal

Wiring Outputs:

• White Wire: Ground
• Brown Wire: Tail
• Yellow Wire: Left Turn/Brake
• Green Wire: Right Turn/Brake
• Red Wire: Stop (for 3-wire systems only)

Safety Notes:

• Always read and follow all warnings and instructions included with the product and the vehicle's manual.
• Do not exceed the manufacturer’s towing capacity or the product’s amperage ratings.
• Wear safety glasses and use all necessary safety precautions during installation.

Troubleshooting Guide:

• 4-Flat Not Functioning: Ensure input wires are correctly installed and repeat testing after removing the 15 amp fuse for 10 seconds.
• No Power to 4-Flat: Check the chassis ground and ensure the module is properly connected to a constant power source.

Specifications:

• Installation Time: Approximately 45 minutes
• Compatibility: Does not work with multiplex vehicles (BM, BT, or BTT). Use part numbers 119190 or 119250 for these systems.

Attention: This is a summary of the installation procedure. For complete installation instructions, including diagrams and detailed information from the manufacturer, please download the full installation PDF.

For technical support and assistance, our team of experts is available to help. You can reach our tech support by visiting www.trailerjacks.com or calling 877-869-6690.

For warranty information, please download the full installation PDF.