This is my experience with mounting a trailer hitch on my 2013 Mazda CX-9 GT AWD. The first part (rusted nuts) is generally applicable to any vehicles with built-in nuts for mounting the hitch and probably many other scenarios. The second part provides information about one more snag in my particular vehicle (the spare tire hoist getting in the way).
I hope that the information is useful and complete; do not hesitate to contact me if further details are needed. Also letting me know if this helped would be appreciated.
My vehicle came with a “towing package”, meaning changes to the cooling system and partial wiring (to the back of the vehicle). However, strangely enough this package include neither a trailer hitch nor the end electrical harness. Fortunately, these parts are not expensive so I went to the good ol' eBay and purchased them.
The wiring was a simple matter of following the instructions. The trailer hitch on the other hand is supposed to be screwed into nuts provided for this purpose under the vehicle. It sounds pretty simple, but the problem is that those nuts have been sitting underneath the vehicle exposed to the elements (including healthy doses of road salt in the winter) for some 4 years, and so were full of rust and who knows what other gunk. Advice to deal with this matter gathered from the 'Net includes the following:
Here is my refinement of this advice. My experience shows that the first step is obviously a must, but contrary with what many people are saying will not solve the problem. The second step will work most of the time but it is dangerous (see below), so your first choice after the wire brush cleaning should be the tap. This is how the tap worked for me:
If for some reason you do not want or cannot use a tap, you can try using a screw to unplug the nut. This is however a dangerous process. Indeed, stripping the screw is a very real possibility, and if you do so consider yourself lucky since other outcomes include stripping the nut or breaking the screw in the nut, both of which will be very difficult to fix. This being said, both the nuts and the screws are pretty strong, so such an approach is possible for this particular application. In my case I used it for the two M8 screws since I was unable to fit a long enough arm on the M8 tap. I used at first the aforementioned 12-inch arm to drive the screw in but I got stuck pretty early in the process, so I switched to an impact wrench. That worked in the end, but I recommend extreme caution since stripping or breaking become very real possibilities:
The above information should be generally applicable. For my particular CX-9 I had to overcome one extra hurdle: the driver side nuts are easily accessible, but the passenger side ones not so much. You will find a box in your way, which happens to be the spare tire hoist. A flat wrench might fit in between the hoist and the frame, but forget about a tap or the torque wrench that will definitely be needed for the final tightening of the screws. I found that the easiest approach is to remove the hoist and put in back once the trailer hitch is secured on the vehicle. This would proceed as follows:
Installation (after mounting the trailer hitch) is obviously the reversal of the removal. I was able to use the old nuts, but that may or may not be your case so have some new nuts available just in case.