Installation Instructions for Lexus ES350 (Excluding Hybrid Models)

Part Numbers:

• 36530
• 90227
• 06154

Wiring Access Location:

• PC3, PC4

Tools Required:

• Wrenches: 10mm, 12mm, 13mm, 14mm, 17mm, 11/16", 3/4"
• Pull Wires (provided)
• Tin Snips
• Lubricant or Soapy Water
• Drill with 1/4" and 1" Bits

Step-by-Step Instructions:

1. Lower Exhaust:

   • Detach the exhaust system at the rubber isolators in 4 locations.
   • Spray lubricant on the metal hanger rod and rubber isolator to ease removal.
   • Support the exhaust system.
   • Lower the exhaust further by removing the hanger behind the passenger-side muffler and the next hanger using a 12mm socket.

2. Loosen Exhaust Hangers:

   • Loosen the exhaust at the hanger brackets using a 14mm socket (3 locations on each side).

3. Remove Heat Shields:

   • Remove the heat shields and set them aside for reinstallation.

4. Test Fit Hitch:

   • Temporarily raise the hitch into position over the exhaust.
   • Loosely install the 1/2" fasteners to the vehicle hanger brackets.
   • Use the additional 1/2" flat washers as needed to account for vehicle variance.
   • Push the forward brackets into place against the bottom of the vehicle frame.
   • If the forward hole (on both sides) does not align with an existing frame hole, mark the hole location using the hitch as a template.

5. Drill Holes:

   • Lower the hitch and drill a 1/4" pilot hole and a 1" access hole as needed.
   • Mark and drill the heat shield for the 7/16" carriage bolt.

6. Fishwire Hardware:

   • Insert the carriage bolts and blocks into the frame rail using the provided pull wires (see Figure 2).
   • Leave pull wires attached.

7. Reinstall Hitch:

   • Raise the hitch back into position and loosely install the 1/2" fasteners to the vehicle hanger brackets.
   • Feed the pull wires through the hitch brackets and install the remaining fasteners.

8. Reinstall Heat Shields:

   • Reinstall the heat shields removed in Step 3.

9. Tighten Fasteners:

   • Torque all 7/16"-14 GR5 fasteners to 50 ft-lb (68 N*m).
   • Torque all 1/2"-13 GR5 fasteners to 75 ft-lb (102 N*m).

Hardware List:

• (2) Hex Bolt, 1/2"-13 x 1.75" GR5
• (2) Carriage Bolt, 7/16"-14 x 1.50" GR5
• (2) Spacer Blocks, 1" x 2"
• (4) Flat Washers, 1/2"
• (2) Conical Washers, 7/16"
• (2) Conical Washers, 1/2"
• (2) Hex Nut, 7/16"-14
• (2) Hex Nut, 1/2"-13
• (2) Hex Bolt, M6 x 1.00 x 16mm (for heat shields)

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 (1,589 kg)
• Max Tongue Weight: 300 lb (136 kg)
• Drawbar must be used in the RISE position only.

Additional Notes:

• Drawbar Kit: 36071 (sold separately)
• Fastener Kit: 36530F
• This product complies with V.E.S.C. Regulation V-5 and SAE J684 safety standards.

Installation Instructions for T-Connector Adapter for LEXUS ES 300h & LEXUS ES 350

Part Numbers:

• 118592

Tools Required:

• Trim Panel Remover
• 10mm Socket & Ratchet or 10mm Wrench
• Drill (3/32” Drill Bit)
• Wire Crimpers
• Wire Cutters
• Phillips Head Screwdriver
• Test Probe

Step-by-Step Instructions:

1. Open the Trunk:

   • Remove the threshold panel.
   • On both the driver and passenger sides, remove two 10mm bolts and partially remove the felt trunk liner to expose the vehicle’s taillight wiring harness.

2. Locate the Taillight Wiring Harness:

   • On the driver’s side, locate the vehicle’s taillight wiring harness.
   • Separate the connectors carefully, ensuring not to break the locking tabs.
   • Ensure that the mating surfaces of the vehicle harness connectors match the T-Connector ends and are clean.

3. Connect the Driver-Side T-Connector:

   • Attach the T-Connector with the yellow and brown wires between the driver’s side wiring connectors.
   • Ensure the connectors are fully inserted with the locking tabs in place.

4. Route the Passenger-Side T-Connector:

   • Route the T-Connector containing the green wire below the threshold cover to the passenger’s side taillight housing.
   • Repeat Steps 2 and 3 using the T-Connector ends containing the green and red wires.

   Note: Route the 4-flat connector through the driver’s side trim panel into the side storage compartment and store it there when not in use.

5. Mount the Black Box:

   • Locate a flat surface on the driver’s side in an out-of-the-way location.
   • Mount the T-Connector’s black converter box with the provided double-sided tape.

6. Ground the White Wire:

   • Locate a suitable grounding point on the driver’s side near the connectors.
   • Drill a 3/32” hole and secure the white wire with the provided eyelet and screw.

   Caution: Verify what is behind any surface prior to drilling to avoid damage or injury.

7. Connect the Power Wire:

   • On the driver’s side, locate the red 12-gauge power wire from the T-Connector box.
   • Attach the black 12-gauge wire provided using the supplied yellow butt connector.

8. Route the Black Wire:

   • Either route the black wire through a grommet and along the exterior frame or follow existing wiring along the thresholds to the engine compartment up to the battery, avoiding areas that may pinch or damage the wire.

   Warning: Avoid hot pipes, heat shields, fuel tanks, or other areas that may damage the wire.

9. Connect to the Vehicle Battery:

   • Disconnect the vehicle’s negative (-) battery cable.
   • Attach the yellow fuse holder to the positive (+) battery cable using the provided ring terminal.
   • Connect the black wire to the fuse holder using the provided yellow butt connector.
   • Insert the 10-amp fuse into the fuse holder.

10. Reconnect the Battery:

    • Reconnect the vehicle’s negative (-) battery cable.

    Warning: Ensure all connections are complete for the T-Connector to function properly. Test the installation with a test light or trailer.

11. Secure the Wiring:

    • Secure the T-Connector harness with the provided cable ties, avoiding areas that could pinch, cut, or melt the wires.

12. Reassemble the Vehicle:

    • Reinstall the plastic trim panels, threshold, storage covers, floor covering, and any other items removed during installation, ensuring no wires are pinched or damaged.

Specifications:

• Max. stop/turn light: 1 per side (2.1 amps)
• Max. tail lights: 5.6 amps

Safety Notes:

• Overloading circuits can cause fires. Do not exceed the towing manufacturer’s ratings or specified circuit ratings.
• Always wear safety glasses and follow safety precautions during installation.

Manufacturer Notes:

• Refer to the vehicle owner’s manual and instruction sheet for additional details.
• Store these instructions for future reference.