Vanlife Northwest

INSTALLATION - Pluto Hitch - Variant 1

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INSTALLATION - PLUTO RECEIVER HITCH - Variant 1

COMPATIBLE MODELS:

  • KZH100, KZH106, KZH110, KZH113, KZH116, KZH120, KZH126, KZH132, KZH138, LH100, LH107, LH123, LH129


COMPONENTS:

  • Receiver hitch

  • (3) M14 x 1.5 x 45mm hex bolts

  • (3) M14 x 1.5 hex nuts

  • (3) M14 flat washers

  • (3) M14 split lock washers

  • (2) M14 toothed star lock washers

  • (1) M14 square flat washer

  • (2) M12 x 1.25 x 35mm hex bolts

  • (2) M12 flat washers

  • (2) M12 split lock washers

  • (1) reinforcement plate

  • (1) rubber patch cover


TOOLS:

  • 1-3/4” hole saw

  • Step drill bit (up to 16mm or 5/8”)

  • 3/16” drill bit

  • Drill motor

  • Center punch

  • Hammer

  • 22mm or 7/8” box end wrench

  • 22mm or 7/8” socket with ratcheting wrench

  • 19mm or 3/4” socket with ratcheting wrench

  • 14mm socket with ratcheting wrench

  • 12mm deep socket with ratcheting wrench

  • 12mm socket with ratcheting wrench

  • 12mm box end wrench

  • Torque wrench (up to 110 ft/lbs)

  • #2 Phillips screw driver

  • Grease

  • Penetrant oil

  • Sharpie marker

  • Rat tail file

  • Spray paint

  • Telescoping magnet tool

  • Adjustable pliers


DIRECTIONS:

  1. Remove the bumper.

    1. Open rear door hatch.

    2. Remove the (2) phillips screws on the inner curves of the plastic bumper cover.

    3. (from underneath) Identify and remove the (4) 12mm head bolts attaching metal bumper frame to the REAR unibody member.

    4. While supporting the bumper, pull outwards on the outer corners of the plastic bumper cover. The bumper has (2) plastic snaps on each side of the bumper cover holding it in place.

    5. Remove the bumper assembly.

    6. Soak the (8) 12mm head bolts that attach the plastic bumper cover to the metal bumper frame with penetrating oil. NOTE: these bolts are often rusty, so this will prevent damage to the plastic bumper cover when removing them later.

    7. Lower the spare tire carrier, and remove the spare tire.

  2. Remove the stock recovery point bracket.

    1. Using the 14mm socket wrench, remove the (2) bolts mounting the stock recovery point bracket. NOTE: if your van doesn’t have this bracket currently installed, we advise you chase/clean the threaded holes with a M12 x 1.25 tap.

    2. Discard the bracket and bolts.

  3. Drill access hole.

    1. Identify the LEFT rectangular cavity in the rear unibody.

    2. Using the hole saw, drill a 1-3/4” hole in the left rectangular cavity. NOTE: this hole must be aligned to the RIGHT section of the LEFT rectangular cavity.

    3. De-bur the hole with the rat tail file.

  4. Drill mounting holes.

    1. Remove the (1) 12mm head bolt from rear mounting point of the fuel tank inlet hose cover.

    2. Align the provided stencil flush with the LEFT edge of the unibody member, and flush with the rear flange of the unibody member. NOTE: the curved end of the stencil will be oriented towards the REAR LEFT corner of the van.

    3. Using the provided stencil and a marker or paint pen, trace the (2) holes to be drilled in the underside of the unibody.

    4. Using the center punch, approximate the center of the (2) holes and make (2) corresponding divots with the punch. These will be used to center your drill bit.

    5. Drill a pilot hole with the 3/16” drill bit in the center of each of the (2) corresponding mounting holes.

    6. Using the step drill bit, drill a 16mm (or 5/8”) hole in each of the (2) corresponding mounting holes.

    7. De-bur the holes with the rat tail file.

    8. Using the magnet, remove all metal shavings inside the unibody frame members.

  5. Paint holes.

    1. Using the spray can, paint the access and mounting holes with 2-3 coats of paint.

  6. Install the hitch.

    1. Orienting the notched corner towards the FRONT LEFT of the van, insert the reinforcement plate into the unibody via the 1-3/4” access hole.

    2. With assistance from a friend, lift the hitch into place.

    3. Thread in the (2) M12 bolts into RIGHT unibody member (where you removed the stock recovery point bracket).

      1. Bolts should have (1) split lock washer and (1) flat washer.

      2. Use a small dab of grease or blue thread locker on the threads.

      3. Only tighten the bolts finger tight.

      4. The RIGHT side of the hitch is now being supported.

    4. Insert (1) M14 bolt through the mounting hole in the left hitch support arm. NOTE: this hole corresponds with the welded recovery slotted eyelet attached to the LEFT unibody member.

      1. Order of fasteners is as follows:

        1. M14 bolt

        2. Left hitch support arm

        3. Recovery slotted eyelet

        4. Square flat washer

        5. Round flat washer

        6. Split lock washer

        7. Nut

      2. Only tighten the bolt finger tight.

    5. Support the left side of the hitch with a jack.

    6. Insert (1) M14 bolt in the FRONT mounting hole in the left hitch support arm.

      1. Bolt should have (1) split lock washer and (1) flat washer.

      2. Bolts should have a small dab of grease on the threads.

      3. Using your telescoping magnet tool, install (1) toothed star lock washer on the TOP side of the M14 bolt. NOTE: you’ll need to hold the bolt in place to keep it from falling back through the hole.

      4. Using your telescoping magnet tool, install (1) M14 nut on the TOP side of the M14 bolt, finger tight. NOTE: be sure not to cross thread the nut.

    7. Repeat to install last M14 bolt in REAR mounting hole.

    8. Using your torque wrench, tighten the (2) adjacent mounting bolts to 120 ft/lbs

      1. First tighten the FRONT bolt, then the REAR bolt.

      2. Using a 22mm (or 7/8”) box end wrench to secure the FRONT mounting nut, torque the bolt with a 22mm (or 7/8”) socket and torque wrench to 120 ft/lbs.

      3. Repeat for the REAR mounting nut.

      4. Double check torque on both bolts.

    9. Tighten the bolt on the recovery slot eyelet to 120 ft/lbs

    10. Tighten the (2) M12 bolts on the RIGHT hitch support arm to 80 ft/lbs

  7. Reinstall the bumper.

    1. Install adhesive backed rubber cover over the LEFT rectangular cavity in the rear unibody.

    2. Separate the plastic bumper cover from the metal bumper frame.

      1. Remove the (8) 12mm head bolts that attach the plastic bumper cover to the metal bumper frame. NOTE: it may be necessary to hold the clip nut end with pliers as you remove the bolts to keep it from spinning and damaging the plastic bumper cover mounts.

    3. Install the metal bumper frame onto the rear unibody member using the (4) 12mm head bolts.

    4. Slide the plastic bumper cover onto the metal bumper frame, and snap the outer ends of the plastic bumper cover onto the unibody corners.

    5. Install the (5) upper 12mm head bolts through the metal bumper frame into the corresponding clip nuts in the plastic bumper cover using a deep 12mm socket and wrench.

    6. Install the lower (3) 12mm head bolts through the metal bumper frame into the corresponding clip nuts in the plastic bumper cover using a 12mm box end wrench.

    7. Install the (2) phillips screws on the inner curves of the plastic bumper cover.

    8. Reinstall the spare tire.