1997-2005 Dodge Installation Instructions

1. Release the hood latch and lift the hood of the vehicle.

2. Refer to Figure 1. Locate the brake lines connected to the brake master cylinder.

3. Refer to Figure 2. There is a service tee included in the hookup kit. The Dodge installation seems to be easier if the forward brake line is used for the service tee.

4. Refer to Figure 3. Remove the brake line from the master cylinder. Install the service tee into the master cylinder. Tighten securely. Reinstall the brake line to the end of the service tee. Tighten securely.

5. Install the brake hose to the side port of the service tee as shown in Figure 3.

6. Refer to Figure 4. Position the hose fitting to avoid abrasion with surrounding objects. Tighten securely.

7. Install the pressure sensor included in the kit to the end of the brake hose. Hand tighten only.

8. Bleed entrapped air from the brake hose by the following procedure. Have someone apply and hold pressure on the brake pedal. Wrap a rag or paper towel around the pressure sensor and open the connection by hand. Brake fluid and air will escape as the brake pedal is depressed to the floor of the

The BrakeSmart Co. www.brakesmart.net info@brakesmart.net

817-456-8773

BrakeSmart BrakeSmart

Figure 1

Figure 2

Figure 3

Figure 4

vehicle. Close off the connection at the pressure sensor hand tight. Have the helper release the brake pedal. Repeat the bleed procedure a second time. Tighten the pressure sensor securely to the brake hose.

9. Install the pressure sensor harness provided in the kit to the pressure sensor electrical receptacle..

10. Figure 5 shows an access hole drilled through the firewall of the vehicle to allow entry of the pressure sensor harness to the brake controller. If another access route cannot be used, this is the preferred method of routing the harness. An 11/16” diameter hole is required. The location shown is to the left of the steering column. Drilling a 1/4” pilot hole before using a larger bit is helpful. A step bit is shown in the picture, however, any bit suitable in size and suitable for steel will work.

11. Remove the cord restraint nut from the cord restraint on the pressure sensor harness. Feed the white connector of the harness through the hole drilled in step 10 .Figure 5 shows the cord restraint of the harness penetrating the firewall. From the interior of the vehicle slide the cord

restraint retaining nut over the harness and tighten securely to the cord restraint.

12. Pull excess slack of the harness from inside the interior of the vehicle. Route the harness in a secure location in the engine compartment and secure to other harnesses or stationary lines in the engine compartment using wire ties provided. Avoid moving objects such as the steering sector and hot objects such as the exhaust system.

13. Plug the power harness for the brake controller into the factory towing socket at the location shown in Figure 6. This wiring panel is located on the drivers side near the kick panel of the interior.

14. Plug the pressure sensor harness, key side up as shown in Figure 7, into the brake controller. Plug the power connector into the brake controller. The power connector will only fit one way.

15. The two pin connector on the controller is reserved for future use. The round port hole on the controller is used to reprogram the unit and also accommodates an Exhaust Gas Temperature and Boost module option for diesel engines.

16. Find a suitable location for the brake controller. This should be a place easily visible by the driver and also allow easy access to the control buttons of the controller.

17. Mount the brake controller mounting bracket at the chosen location using the two self drilling screws provided.

18. Start the engine and depress the brake pedal. “Braking” should appear on the top line of the brake controller. A bar graph appears on the bottom line of the display. As pressure is increased on the brake pedal, the bar graph extends to the right on the display.

19. Inspect the brake line connections to assure there are no leaks.

20. Close the hood. 21. Stop the engine. 22. Installation complete. 23. Enjoy the many features of your new

brake controller.

Figure 7

Figure 5

Figure 6