Trailer Tow Wiring/Components - Installation Cautions

91chrysler04

NO.: 08-05-91

GROUP: ELECTRICAL

DATE: Apr. 22, 1991


SUBJECT: Trailer Tow Wiring Installation


MODELS:

ALL DODGE TRUCKS


DISCUSSION:

Improper installation of trailer tow wiring or electrical components can cause erratic operation of the vehicles electrical system. When installing wiring or additional components, or diagnosing a vehicle with erratic electrical operation, observe the following guidelines.

^ Inspect trailer wiring for bare or broken wires, corroded splices and terminals, shorted lamp sockets, poor or insufficient grounding between the trailer wiring system and trailer frame.

^ When connecting lighting circuits, use a factory trailer tow wiring harness or a Mopar service kit if available. Mopar kits include mating connectors and do not require cutting or splicing of vehicle wiring. If cutting or splicing is required, the attached Wiring Procedure should be followed.

^ When installing any electrical equipment (such as electric brakes, battery chargers, lighting, and winches) make sure that the tow vehicles electrical ground is hard wired to the trailer electrical ground. Ground wires should be attached to a clean, bare metal surface, not to a painted surface. DO NOT rely on the trailer hitch coupling for ground.

^ When using butt splice connectors, test the splice integrity by pulling on the wires after crimping.

^ DO NOT use insulation displacement or insulation piercing crimp type terminals.

^ Some electrical equipment will require splicing into the vehicle wiring. Follow the attached Wiring Procedure when installing these components.





WIRING PROCEDURE


1. With the ignition key in the OFF position, disconnect the battery.

2. Remove one inch of insulation from each wire to be connected.

3. Slide a piece of heat shrink tubing (PN 4419644) onto one wire.

4. Spread the strands of each wire apart (Example 1).

5. Push the ends of the wire together until the strands are close to the insulation (Example 2).

6. Twist the wires together (Example 3).


7. Solder the twisted wire ends using a ROSIN CORE SOLDER.

8. Slide the piece of heat shrink tubing down to cover the splice. Be careful to center the tubing on the splice. Using a heat gun, heat the tubing until it shrinks and seals the splice.

9. Connect the battery.