adsm08
Senior Master Grease Monkey
Supporting Member
Article Contributor
Ford Technician
TRS 20th Anniversary
- Joined
- Sep 20, 2009
- Messages
- 34,623
- Reaction score
- 3,613
- Points
- 113
- Location
- Dillsburg PA
- Vehicle Year
- 1987
- Make / Model
- Ford
- Engine Type
- 4.0 V6
- Engine Size
- 4.0
- Transmission
- Manual
- 2WD / 4WD
- 4WD
- Tire Size
- 31X10.50X15
Original Poster:* adsm08
Difficulty: 4 out of 10
Time to install:*Took me about 3 hours, but I kept getting interrupted.
Disclaimer: The Ranger*Station.com, The Ranger*Station.com*Staff, nor the original poster are responsible for you doing this modification to your vehicle. By doing this modification and following this how-to you, the installer, take full responsibility if anything is damaged or messed up. If you have questions, feel free to PM the original poster or ask in the appropriate section of The Ranger*Station.com*forums.
Brief Explanation: The idea of this write up is to show how to flush mount a 7-pin trailer connector into the rear bumper of 83-92 Rangers. It will probably work on other years, but I don't have those bumpers here to test that theory.
Tools Needed:
-*Drill/ good bits
-*Knife/box cutter
-*Good hole saw, 2 1/8 inch was the size I needed. Size it to the hole in your mounting bracket
-grinder (optional)
-screw driver
-socket set
Parts Needed:
-*7-pin plug kit. I used a Hopkins 7-pin/ flat 4 combo unit.
-Longer screws (optional)
---------------------------------------------------------
Step 1: Measure out the proper position of the hole for the plug itself.. I removed the cover to make the hole and then measured it out so those after me wouldn't have to.
Position of hole if you remove the cover:
Position of hole if you measure from the front:
This position is critical. Too far to the left and you hit a brace. Too far to the right and you have a carriage bolt in your way. This also puts it away from everything behind the bumper. This provides a lot of good protection because the curl of the bottom of the bumper is almost exactly the same length as the plug.
Measured with the tape hooked to the inboard edge of the over.
Measured with the tape hooked to the top edge of the cover.
---------------------------------------------------------
Step 2: Cut the angle portion off the mounting bracket. (Optional)
---------------------------------------------------------
Step 3: Once you have made your measurements use the hole saw to drill out the cover. In my case I had to use a different bit to drill through the bumper because the pilot on my hole saw sucks. I knew this going into it so I put the cover back on the bumper to make my pilot hole in the bumper at the same time.
---------------------------------------------------------
Step 4: Next install the cover (if removed), install the plug in the bumper and use it's screw holes as a template to drill pilot holes for the screws.
The lower holes were more difficult because they landed right on the corner of where the bumper angles under the cover. I used the mounting bracket to help hold the drill bit stable.
---------------------------------------------------------
Step 5: This is where things can go one of two ways. If you have longer screws just drill holes and install screws. If you are using the screws that came with the kit there is more to do. With the cover in place and the plug sitting over it the screws in the kit just sit flush with the metal of the bumper. This means the cover has to be cut out so the plug can sit in the hole and right against the metal.
NOTE: At this point you should have a circular hole in your plastic for the plug and 4 holes for the screws either way.
To cut the square hole out you should hold the plug in the hole with at least two screws in and trace it out. Then cut it out. I ended up using a die-grinder because I didn't have anything else good to use.
Once I had the hole cut I trimmed it back until the plug fit through easily. It was important in my case that it fit easily the whole way through because my base is tapered.
---------------------------------------------------------
Step 6: Once the plug fits through your hole properly and easily install the plug on the bumper and put the screws in loosely. Then reinstall the bumper cover around the plug.
Wire as per kit instructions. My truck at a functional flat 4 already so I used a kit that plugs into an existing flat 4 for the lighting.
Test all functions for proper operation before towing.
---------------------------------------------------------
Difficulty: 4 out of 10
Time to install:*Took me about 3 hours, but I kept getting interrupted.
Disclaimer: The Ranger*Station.com, The Ranger*Station.com*Staff, nor the original poster are responsible for you doing this modification to your vehicle. By doing this modification and following this how-to you, the installer, take full responsibility if anything is damaged or messed up. If you have questions, feel free to PM the original poster or ask in the appropriate section of The Ranger*Station.com*forums.
Brief Explanation: The idea of this write up is to show how to flush mount a 7-pin trailer connector into the rear bumper of 83-92 Rangers. It will probably work on other years, but I don't have those bumpers here to test that theory.
Tools Needed:
-*Drill/ good bits
-*Knife/box cutter
-*Good hole saw, 2 1/8 inch was the size I needed. Size it to the hole in your mounting bracket
-grinder (optional)
-screw driver
-socket set
Parts Needed:
-*7-pin plug kit. I used a Hopkins 7-pin/ flat 4 combo unit.
-Longer screws (optional)
---------------------------------------------------------
Step 1: Measure out the proper position of the hole for the plug itself.. I removed the cover to make the hole and then measured it out so those after me wouldn't have to.
Position of hole if you remove the cover:
Position of hole if you measure from the front:
This position is critical. Too far to the left and you hit a brace. Too far to the right and you have a carriage bolt in your way. This also puts it away from everything behind the bumper. This provides a lot of good protection because the curl of the bottom of the bumper is almost exactly the same length as the plug.
Measured with the tape hooked to the inboard edge of the over.
Measured with the tape hooked to the top edge of the cover.
---------------------------------------------------------
Step 2: Cut the angle portion off the mounting bracket. (Optional)
---------------------------------------------------------
Step 3: Once you have made your measurements use the hole saw to drill out the cover. In my case I had to use a different bit to drill through the bumper because the pilot on my hole saw sucks. I knew this going into it so I put the cover back on the bumper to make my pilot hole in the bumper at the same time.
---------------------------------------------------------
Step 4: Next install the cover (if removed), install the plug in the bumper and use it's screw holes as a template to drill pilot holes for the screws.
The lower holes were more difficult because they landed right on the corner of where the bumper angles under the cover. I used the mounting bracket to help hold the drill bit stable.
---------------------------------------------------------
Step 5: This is where things can go one of two ways. If you have longer screws just drill holes and install screws. If you are using the screws that came with the kit there is more to do. With the cover in place and the plug sitting over it the screws in the kit just sit flush with the metal of the bumper. This means the cover has to be cut out so the plug can sit in the hole and right against the metal.
NOTE: At this point you should have a circular hole in your plastic for the plug and 4 holes for the screws either way.
To cut the square hole out you should hold the plug in the hole with at least two screws in and trace it out. Then cut it out. I ended up using a die-grinder because I didn't have anything else good to use.
Once I had the hole cut I trimmed it back until the plug fit through easily. It was important in my case that it fit easily the whole way through because my base is tapered.
---------------------------------------------------------
Step 6: Once the plug fits through your hole properly and easily install the plug on the bumper and put the screws in loosely. Then reinstall the bumper cover around the plug.
Wire as per kit instructions. My truck at a functional flat 4 already so I used a kit that plugs into an existing flat 4 for the lighting.
Test all functions for proper operation before towing.
---------------------------------------------------------
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