Please read these Installation Instructions in their entirety prior to installing or operating this equipment.

Transcription

1 Please read these in their entirety prior to installing or operating this equipment. This hitch is rated to 30,000 lbs. Gross Towing Weight and 7,500 lbs. Tongue Weight Bolt Torque Specifications Torque in Foot-Pounds for Inch Bolts Bolt Size Grade 5 Grade 8 1/ / / / / / / Bolt Torque Specifications Torque in Foot-Pounds for Metric Bolts Bolt Size Grade 8.8 Grade MM 6 8 8MM MM MM MM MM MM ! WARNING! Refer to your vehicle s owner s manual for maximum towing capacity. DO NOT exceed vehicle, tongue or hitch weight ratings - failure to follow vehicle manufacturer s recommendations could result in damage to your vehicle, personal injury or death. Page 1 of 9 WARNING Failure to read and follow these instructions could result in separation of the trailer from the truck, causing property damage, loss of towed vehicle, personal injury or death.

2 ! WARNINGS Trailer brakes are required. Do not use any open flame under the truck bed to cut or weld. There is extreme danger of explosion or fire. Vehicle must be securely blocked and brakes set before beginning to work underneath the vehicle. Do not clamp hitch over any wiring or brake lines. Always make sure trailer is loaded slightly tongue heavy. Do not pull a trailer that is lighter on the tongue end. Always insure the hitch ball is locked into the hitch prior to towing. Maintenance/Care Periodically clean any dirt/debris from the ball and ball housing and moderately lubricate them with white lithium grease or equivalent grease. Instruction Notes: The exhaust hangers are removed and reinstalled for the hitch installation. Some drilling and trimming is required. Place all components that are removed on a flat, sturdy surface. All items will be reinstalled unless otherwise noted after the hitch is installed. The dimensional variations between otherwise identical vehicles can be considerable. While this hitch was designed for easy installation, it may be necessary to modify the hitch slightly to compensate for vehicle manufacturer s tolerances. NOTICE When a bed liner is installed, compensation of the bed liner thickness must be accounted for when measuring the ball location in the box bed. When using power drills be aware of the dangers of torque and drill bit length. When using a reciprocating saw be aware of objects behind the cutting surface. Use a good quality paint to spray cut edges of frame to prevent rusting. Be sure to use a sufficient amount of Loctite Red on all bolts before tightening. Tighten all bolts according to the torque chart provided. The installer must instruct the operator on proper ball installation and locking procedures. Dealer or installer be certain the user receives these instruction sheets. If the hitch is in an accident, it must be replaced. DO NOT use it again! An accident can cause unseen damage and using it again could result in more damage or serious injury. DO NOT use the hitch if it is damaged or missing parts. When inverting the ball, ensure proper clearance between the ball and the truck s differential and drive line. Failure to do so may result in damage. A plug is included with all Blue Ox Gooseneck Hitches that can be used for covering the socket when the ball is removed. Page 2 of 9

3 Tools Required Torque Wrench Drill Tape Measure Loctite RED 5 Hole Saw 19/32 Drill Bit 3/4 Socket 3/4 Wrench 15/16 Socket T25 Torx DH Front of Vehicle Item No. Part No. Description Qty /8 Nut Wire DH2204 Front DS Cross Member DH2204 Front PS Cross Member DH2204 Rear DS Cross Member DH2204 Rear PS Cross Member Hitch Ball DH2204 Center Section DH2204 DS Side Plate DH2204 PS Side Plate DH2204 Cross Member Joint Plate DH2204 Front Cross Member Joint Plate DH2204 DS Chassis Bracket 2WD Plate DH2204 PS Chassis Bracket 2WD Plate /8-11 x 4-1/2 Hex Head Bolt, Grade 5, ZP /2-13 x 1-1/4 Carriage Bolt, Grade 5, ZP /2-13 x 1-3/4 Carriage Bolt, Grade 5, ZP /2-13 x 3-3/4 x 2-1/2 U-Bolt, ZP /8-11 x 1-3/4 Hex Head Bolt, Grade 5, ZP /8-18x 1-1/4 Hex Head Bolt, Grade /2-13 Hex Flange Whiz Lock Nut, ZP /8-11 Hex Flange Whiz Lock Nut, ZP /2-13 Hex Nylon Lock Nut, Grade 8, ZP /2 Flat Washer, ZP /8 Flat Washer, ZP Compression Spring (.85 Dia x.05 x 2 ) Ball Housing Plug /2 Black Polypropylene Tape...1 Important: Use only genuine factory replacement parts on your hitch. Do NOT substitute homemade or non-typical parts. If a bolt is lost or in need of replacement, for your safety and the preservation of your hitch, be sure to use a replacement bolt of the same grade (In most cases it will be Grade 5, please reference the parts list above). 19 Page 3 of

4 1. Using the vehicles jack handle tool, remove the spare tire as per vehicles owners manual. 2. Lower the exhaust by removing four (4) bolts with a 10mm socket and reinstalling two (2) of them into lower holes. 3. Using a 5 Whole saw, drill out a hole in the top of the truck bed using the dimple in the bed as a locator. 4. Using a grinding stone, or file, deburr all edges thoroughly in order to allow ball housing to protrude through the truck bed hole. Page 4 of 9

5 5. Take the four (4) cross member weldments and insert the 1/2 x 1-1/4 long carriage bolts into the top square holes. 6. Slide the front two (2) cross member weldments into place and join together using the front joint plate. Apply appropriate hardware but leave loose. 7. Slide the rear two (2) cross member weldments into place and join together using the rear joint plate. Apply appropriate hardware but leave loose. The passanger side cross member will need to be slid into place before the drivers side. 8. Apply the polypropylene tape around the collar of the center section. Be sure that the collar still functions properly afterwards. Page 5 of 9

6 9. Raise the center section into place, aligning with the hole in the bed and attach to cross members on both sides with appropriate hardware. Using a 3/4 socket loosely tighten hardware. 10. Install side plates using appropriate hardware and loosely tighten using a 15/16 socket and wrench. The vertically orientated bolts will require that the nuts are placed on top and the bolt and washers inserted from underneath. Note: If the truck is two (2) wheel drive, the 2WD chassis brackets ( & ) will need to be installed as well at this time. The 4WD models do not require this component. 11. Ensure the ball housing functions smoothly and tighten all hardware to torque specifications. Page 6 of 9

7 12. From the bottom side drill a pilot holes for safety chains. Then drill two (2) full size hole with a 1/2 drill bit. Do this on both sides 13. Deburr holes and insert u-bolts from the top side and apply springs, washers, and locking nuts from underneath. Page 7 of 9

8 Installing the Hitch Ball 1. Rotate the locking collar to release the latch pawl. 2. Align the ball with the collar and drop the ball into the hitch. Release the locking collar. Pull up on the ball to insure it is locked into the housing. Removing the Hitch Ball 1. Rotate the locking collar to release the latch pawl. Pull straight up on the ball to remove from the hitch. Page 8 of 9

9 Storing the Hitch Ball 1. Rotate the locking collar to release the latch pawl. Align the ball with the collar and drop the ball into the hitch. 2. Release the locking collar. Page 9 of 9 Learn more about trailer hitches on our website.