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DIY MB Hitch and MB wiring harness install
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Posted 4/6/2010 11:30 PM
Vehicross99
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Date registered: May 2009
Location: So Texas/SW Colorado
Vehicle(s): 2006 G500
Posts: 161
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DIY MB Hitch and MB wiring harness install

Photo DIY trailer hitch install with light wiring harness & brake controller wiring harness installation.
Caution: This post is for entertainment only. Do not try this at home unless you take responsibility for your own work.
Nor do I take responsibility for the lack of entertainment value…..

Many thanks to G-AMG for all his help and use of his specialized tools. (And lift!!) The better photo shots are all his!
Also thanks to everyone else that has posted earlier on various parts of the hitch installation. It helped me along the way on my install.

Parts list
MB Trailer Hitch kit B6 685 0036 (includes light wiring harness)
MB Brake Controller wiring harness B6 685 0051
Draw-Tite harness Part #20127

Here are the install sheets to follow: You will want to download these because they have more detail than I am presenting.
Trailer Hitch install
http://www.fourbyfourclub.com/Manuals/W463TrailerHitchInstallation....
Brake controller wiring harness install
http://www.fourbyfourclub.com/Manuals/Brakes-Electric-Install[1].pd...
Thanks to fourbyfourclub.com.
You will want to pay attention to all the general safety notes & warnings in these 2 documents.

My install was done in 2 steps. We installed the trailer hitch on one day and installed the wiring for the lights & brake controller on another day.

Hitch install
This is Step #8 thru #12 in the Hitch Install sheet.
We found that the hitch could be positioned in place easily and the bolts reached with out removing the bumper so we proceeded with the bumper in place.
In retrospect, if you do not have the specialized tools available (wobble sockets, socket universal joints & extensions), you would be well advised to go ahead and remove the bumper. It gets very hard to correctly torque down the bolts with the bumper in place.

You will want to install all the bolts loose. The side tie bars were the hardest bolts to start. My threaded holes were rusty & needed to be cleaned out with a tap. Once all the bolts are started tighten the side tie bar bolts and then the 4 center bolts.
You will need to tighten them to the required torque.



Edited by Vehicross99 11/21/2019 3:09 PM




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#169346
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Posted 4/6/2010 11:42 PM
Vehicross99
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Date registered: May 2009
Location: So Texas/SW Colorado
Vehicle(s): 2006 G500
Posts: 161
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RE: Photo DIY Hitch and wiring install

Wiring installation
Both the light harness & Brake Controller was done at the same time.
There were 2 items different from the instruction sheets:
1. I had a Bosch unit where the instructions said to mount the relay bracket so I mounted the bracket in the front of the compartment and then mounted the 2 relay assemblies to it.
2. My license plate lights already had full insulators on the connectors.




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#169347 - in reply to #169346
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Posted 4/6/2010 11:45 PM
Vehicross99
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Date registered: May 2009
Location: So Texas/SW Colorado
Vehicle(s): 2006 G500
Posts: 161
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RE: Photo DIY Hitch and wiring install

Wiring continued part 2:

Edited by Vehicross99 4/6/2010 11:51 PM




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#169348 - in reply to #169346
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Posted 4/6/2010 11:52 PM
Vehicross99
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Date registered: May 2009
Location: So Texas/SW Colorado
Vehicle(s): 2006 G500
Posts: 161
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RE: Photo DIY Hitch and wiring install

Wiring continued part 3:



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#169349 - in reply to #169346
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Posted 4/7/2010 12:00 AM
Vehicross99
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Date registered: May 2009
Location: So Texas/SW Colorado
Vehicle(s): 2006 G500
Posts: 161
100
RE: Photo DIY Hitch and wiring install

Next you add the Brake controller wiring harness
Cut the metal CD cover plate for harness exit. 20mm x15mm.
Install plug (2 wires) #4 into #15. (See the install sheets)
Route wiring harness out & to the front under the left trim panel after folding the left rear seat to its upright position. Be careful not to damage the wiring harness.
Pay attention to harness cable shield position.



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#169350 - in reply to #169346
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Posted 4/7/2010 12:04 AM
Vehicross99
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Date registered: May 2009
Location: So Texas/SW Colorado
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RE: Photo DIY Hitch and wiring install

The instructions call for you to trim the sides of the left battery cover but I found there was more than enough clearance on mine.
Pay attention to harness cable shield position.
Attach neg connector to neg terminal pinch bolt.
Attach pos terminal wire to nut on pinch bolt assy.
Run wiring under left side of center console to petal cluster. (Hard to do because of limited access)




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#169351 - in reply to #169346
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Posted 4/7/2010 12:09 AM
Vehicross99
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Date registered: May 2009
Location: So Texas/SW Colorado
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Posts: 161
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RE: Photo DIY Hitch and wiring install

Now you will need to make the Brake Controller universal harness and install it to the MB harness being careful to match up the correct wires. . I used a Draw-Tite harness part #20127



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#169352 - in reply to #169346
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Posted 4/7/2010 12:14 AM
Vehicross99
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Date registered: May 2009
Location: So Texas/SW Colorado
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RE: Photo DIY Hitch and wiring install

Decide on mounting for Brake Controller & run wiring accordingly. The following was my choice.



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#169353 - in reply to #169346
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Posted 4/7/2010 12:20 AM
Vehicross99
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Date registered: May 2009
Location: So Texas/SW Colorado
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RE: Photo DIY Hitch and wiring install

Reassemble everything in the reverse order. (Instruction sheets have that description.)
Connect neg battery terminal
Disconnect Trickle charger.

I did not want to have the electrical connector plate hanging down below the hitch (standard mounting) so I followed Karl’s lead in installing the connector on the bumper.



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Attachments MBHI 026a.jpg (39KB - 8 downloads)
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Attachments MBHI 033a.jpg (32KB - 8 downloads)
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Attachments MBHI 042a.jpg (44KB - 12 downloads)
Attachments MBHI 041a.jpg (36KB - 11 downloads)
Attachments IMG_7049b.JPG (33KB - 10 downloads)
#169354 - in reply to #169346
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Posted 4/7/2010 12:26 AM
Vehicross99
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RE: Photo DIY Hitch and wiring install

That's it!
#169355 - in reply to #169346
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Posted 4/7/2010 1:34 AM
koly
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Date registered: Jul 2006
Location: Scottsdale, AZ USA
Vehicle(s): 2000 G500
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RE: Photo DIY Hitch and wiring install

That's quite the DIY - great write-up!
#169360 - in reply to #169355
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Posted 4/7/2010 5:49 AM
nadd
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Date registered: Apr 2006
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Vehicle(s): G500 2016 LHD, numerous Chevys
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Re: Photo DIY Hitch and wiring install

Great photos and work - must've taken a few hours.

Only thing I would recommend revising is the location of the brake controller. In a crash, that location is often a prime contact area for knees and/or hands. There's a reason why the key hole is recessed like that - to avoid any possible interaction with knees in a crash. I'd hate to have that metal bracket "interact" with any body part in the event of a rollover.
#169373 - in reply to #169346
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Posted 4/7/2010 6:03 AM
bram_r
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Re: Photo DIY Hitch and wiring install

Is this hitch for 463 models or will it also fit the 460/461 range?

Bram
#169374 - in reply to #169346
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Posted 4/7/2010 9:35 AM
Vehicross99
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Re: Photo DIY Hitch and wiring install

nadd,
Brake controller positioning is always a problem since it is an add-on.
I have used the lever in mountain driving, while towing, so its position was important to me.
It would be interesting to see other controller installations.

Bram,
I suspect only 463 but one of the experts should be able to answer that.
#169390 - in reply to #169346
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Posted 7/25/2010 3:15 AM
sharkmobil
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Date registered: Feb 2010
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Re: Photo DIY Hitch and wiring install

You got to be kidding me.
#175183 - in reply to #169346
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Posted 7/25/2010 7:38 PM
DUTCH
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Re: Photo DIY Hitch and wiring install

sharkmobil - 7/25/2010 3:15 AM

You got to be kidding me.


Oh really? How so?
#175204 - in reply to #175183
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Posted 7/27/2010 10:07 AM
G-AMG
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Date registered: May 2006
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Re: Photo DIY Hitch and wiring install

sharkmobil - 7/25/2010 3:15 AM

You got to be kidding me.


Actually, it's not as bad as it looks... there are just alot of steps to it.

The only "difficult" part is the hitch install.

I think if we did it over again, we would have simply removed the bumper, and made a much easier job of it.
#175245 - in reply to #175183
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Posted 7/27/2010 12:18 PM
Vehicross99
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Re: Photo DIY Hitch and wiring install

Yes indeed....I was kidding you!

On top of all this, a while back I had changed out all my lights on the trailer to LEDs. Much better visibility than the old 1959 light units.

BUT....If you have followed any of the towing threads you know that presents unique conditions also.
When hooked up, the trailer lights do work however the brake controller does not.
It seems that the G is looking for resistance in the trailer light curcuit proving that there is a trailer back there to use the brakes on.
Long story short is the availability of cheap adapters to correct this condition for MB, Volkswagen Touareg, Audi Q7, and Porsche Cayenne.
They provide in-line resisters to bypass the factory trailer monitoring system.
I used a Valley Wiring 7-Way to 7-Way Trailer Adapter part #V39010.
They also have 4 & 5 wire adapters for the same purpose.

#175250 - in reply to #175183
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