Blue Ox BX3775 User manual

Page 1 of 6 292-2983 Rev. B 8/31/09
2001-07 Toyota
Highlander
BX3775
1. Blue Ox®towing products and accessories
are intended to be installed by Blue Ox®
Dealers who are familiar with our products and
have the equipment and knowledge to do “fit
work.” When necessary, Blue Ox®Dealers can
be found at www.blueox.us or by contacting
our Customer Care Department at
[phone].
2. Many Blue Ox®Baseplates are designed to
use existing holes and hardware to mount
the baseplate to the towed vehicle. Even
though bolts are there, do not assume they
are adequate for baseplate mounting. Always
use hardware supplied in the hardware kit
or existing hardware specified in the
Baseplate Towing Installation Instructions.
Serial Number
Confirm the towability and pre-towing
procedures for your vehicle with
the owner’s manual or contact the
vehicle’s manufacturer for specific
towing procedures.
Please read BOTH these Installation Instructions and the General Towing
Instructions before attempting to install or operate this equipment.
!
Failure to read and follow these instructions
could result in separation of the towed vehicle
from the tow bar, causing property damage,
loss of towed vehicle, personal injury or death.
WARNING
Attachment Tab Height: 15 1/4”
Attachment Tab Width: 19 1/2”
Bolt Torque Specifications
Torque in Foot-Pounds for Inch Bolts
Bolt Torque Specifications
Torque in Foot-Pounds for Metric Bolts
Bolt Size Grade 8.8 Grade 10.9
6MM 6 8
8MM 16 22
10MM 31 40
12MM 54 70
14MM 89 117
orque Specifi
in Foot-Pounds for Inc
orque Specifi
e in Foot-Pounds for Inc
Torque Specific
e in Foot-Pounds for Met
t Size
Grade 8.8
Grade
6MM
8
8MM
2
2
0MM
40
MM
7
8
Torque Specific
e in Foot-Pounds for Met
t
6
8
0M
0
MM
7
e
G
Gr
ad
e 8
.8
G
n
ize
M
6
1
6
31
54
89
M
rad
8
Bolt Size Grade 5 Grade 8
1/4” 10 14
5/16” 19 29
3/8” 33 47
7/16” 54 78
1/2” 78 119
5/8” 154 230

Important:
Use only genuine factory replacement parts on your baseplate. 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 baseplate, 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). Replacement parts may be ordered
through your nearest Blue Ox® Dealer or Distributor.
Page 2 of 6 292-2983 Rev. B 8/31/09
2001-07 Toyota Highlander
Installation Instructions
BX3775
Tools Required
Loctite®RED Phillips Screwdriver
9/16” Socket Flat Screwdriver
10MM Socket Needle Nose Pliers
13/32” Drill Bit 1 1/4” Hole Saw
Vise Grips
Parts List
Ref. No. Qty. Part # Description
1 1 61-6433 WLDM’T, BASEPLATE, BX3775
2 4 61-5208 WLDT, NUT PLT, 1/4X1X1, 3/8” BLT WIR
3 2 201-0443 3/8-16 X 1 HEX BOLT GRD.5, ZP
4 4 201-0368 3/8-16 X 1 1/4” HEX HEAD BOLT,GRD. 5
5 6 203-0010 3/8” LOCK WASHER, ZP
6 2 202-0003 3/8-16 HEX NUT, ZP
7 1 201-0655 6MM-1.0 X 30MM HEX BOLT, GRD8.8,ZP
8 1 203-0008 1/4” LOCK WASHER, ZP
9 1 203-0001 1/4” FLAT WASHER, ZP
10 2 201-0553 1/4-20 X 1/2’’ HX.WSHD.TYPE F TCS, ZP
11 2 201-0192 10-32 X 1/2” SLOT, RD. HD. SCREW
12 2 203-0054 #10 LOCK WASHER
13 2 202-0047 #10-32 HEX NUT
14 2 101-5822 ADAPTER, 4 WAY CONNECTOR
15 2 62-3468 ATT TAB ASSY, REM, SF/SB, 1 HOLE
2 226-0049 BASEPLATE SAFETY CABLE, 36” CL IV (Not Shown)
4 229-0512 QUICKLINK, 1/2, ZP (Not Shown)
2 290-0437 RECEIVER, CAP PLUG (BLK) (Not Shown)
ELECTRICAL CONNECTOR
6WAYROUND
4WAYROUND
ELECTRICAL CONNECTOR
HOLE NOT USED
DRIVER'S SIDE

1. Using a flat screwdriver, remove four plastic
push pins from the top of the fascia. Set push
pins aside to be reinstalled later.
Vehicle Weight:
The weight of this vehicle is near the Class
III, 5,000 lb. rating limitations. Some models,
depending on options, may well exceed this
5,000 lb. rating. Be sure to confirm the weight of
your individual vehicle before towing. As of 1999,
the Aventa®II is now 10,000 lbs. and either
the Aventa®II or theAventa®LX tow bar must be
used for these applications.
Tow Bar Adapters are NOT to be used with
vehicles weighing over 5,000 lbs.
Installation Notes: The fascia metal
bumper and air baffle are removed and
reinstalled during installation of the baseplate.
Drilling is required. Trimming of the fascia is
required.
The dimensional variations between otherwise
identical vehicles can be considerable.
While the baseplate was designed for easy
installation, it may be necessary to tailor the
baseplate slightly to compensate for auto
manufacturer’s tolerances. These minor
adjustments may include filing a hole slightly,
bending electrical rods and/ or bending end
plates.
The BX8869 Bulb and Socket Wiring Kit is
recommended for this vehicle.
2001-07 Toyota Highlander
Installation Instructions
BX3775
Installation Instructions:
Page 3 of 6 292-2983 Rev. B 8/31/09
2. Using a flat screwdriver, remove two screws
just forward of the front tire, on wheel well.
Using the flat screwdriver, turn the push pin
90oand lift push pin out. Repeat for both
sides of the vehicle. Set screws aside to be
reinstalled later.
1
1
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2
2
3
3
3. Using a 10MM socket, remove one metric bolt
from inside front wheel well on fascia’s upper
corner. Repeat for both sides of vehicle. Set
bolts aside to be reinstalled later.
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4. Using 10MM socket, remove six metric bolts from lower edge of fascia. Do this around the front of
the vehicle.
2001-07 Toyota Highlander
Installation Instructions
BX3775
5. On the passenger side behind the front corner
beside the headlight, using a needle nose
pliers squeeze the push pin together and pop
the front out. Do this on both sides.
Page 4 of 6 292-2983 Rev. B 8/31/09
7. On the passenger side, using a 10MM socket, remove three metric bolts from washer reservoir.
Unplug and set aside water reservoir and bolts for later reinstallation.
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4A
4A
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5
5
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6
6
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6. Just between grill and radiator, using a phillips
screwdriver remove the screw. Pull fascia
corners out to the side of vehicle on both sides
then forward. Set fascia and styrofoam aside
for later reinstallation.
7A
7A
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7B
7B
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4B
4B
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Page 5 of 6 292-2983 Rev. B 8/31/09
2001-07 Toyota Highlander
Installation Instructions
BX3775
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8. On the drivers side, below the stud is a tape
covered hole, drill an 1 1/4” hole to get the
wire nuts through. (Driver’s side shown.) Do
this on both sides.
BE SURE TO USE LOCTITE®RED ON ALL BOLTS
BEFORE TIGHTENING. TIGHTEN ALL BOLTS
ACCORDING TO THE TORQUE CHART ON THE
FRONT PAGE OF THESE INSTRUCTIONS OR ON
PAGE 3 OF THE BASEPLATE TOWING GENERAL
INSTRUCTIONS.
10. On the passenger side, reinstall the washer
reservoir. On the right side (grey arrow),
reattach with a 6MM-1.0 x 30MM hex bolt
and 1/4” lock and flat washers. Reconnect all
hoses and electrical connections.
9. Slide the baseplate straight up from the
bottom, push up as far as possible, adjust to
a level position with the vehicle and clamp
with a vise grip. Align passenger’s side with
existing hole in frame for washer reservoir
(see grey arrow step 10). In the existing hole,
start a 3/8”-16 x 1 1/4” hex bolt with 3/8” lock
washer attached to 1/4” x 1” x 1” nut plate. Do
this to both sides. Some vehicles may have
tape over the existing hole that will need to be
removed. Using the baseplate as a template,
with a 13/32” drill bit drill the other two holes.
In the top hole, insert 1 1/4” hex bolt. In the
bottom, use a 3/8”-16 x 1” hex bolt with 3/8”
lock washer and hex nut. Do the same on the
other side. Tighten with Loctite Red. Please
note bolt locations on passenger’s side. (See
page 2)
11. Attach baseplate safety cables, wrap around
the lower frame extension twice, or as close as
possible. If you are unable to place safety cables
in this position, position the cables around a
solid piece of the frame. 226-0046 base plate
safety cables and 229-0359 quick links are
recommended. Be sure the safety cables do not
rub against any hoses or moving parts.
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8
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9
10
10
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11
11
Using a good quality paint, spray cut edges
of frame to prevent rusting.
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12. Reinstall the styrofoam and bumper.
Reinstall fascia, bolts and push pins.
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Be sure that ALL electrical connections
are plugged in properly and functioning
BEFORE installing the fascia.
Install the tow bar and safety cables
according to the instructions provided in their
packages. When demonstrating to customer,
be sure to include all original content and
packages. Do NOT substitute other devices if
the tow bar pins and clips are misplaced.
DEALER or INSTALLER:
Be certain the user receives the
instruction sheets for their products.
CUSTOMER SERVICE COMMITMENT
Blue Ox is committed to providing you with
exceptional customer care throughout your lifetime
with our products. Our team is here to assist you
with any questions you may have regarding the
performance of your product. Simply call 1-800-
228-9289 and you can speak with our customer
care team.
Additionally, please visit our website to see
which rallies our Destination America team will
be attending. For a nominal fee, our service
technician will service your towing system to
ensure it’s in proper working condition. Also as
a commitment to our customers, should you visit
our factory you can stay at our full service Blue
Ox campground at no charge along with enjoying
a factory tour.
Again thank you for being our customer and for
the confidence you have shown in the performance
of our products. It is because of customers like
you we enjoy the success we have today.
Page 6 of 6 292-2983 Rev. B 8/31/09
2001-07 Toyota Highlander
Installation Instructions
BX3775
Shown without removable tabs installed.
Shown without removable tabs installed.
Shown with removable tabs installed.
Shown with removable tabs installed.
© 2007, 09 Blue Ox
One Mill Road, Industrial Park
Pender, Nebraska 68047
Phone: [phone] • Fax: [phone]
www.blueox.us