1999-2004 Ford Installation Instructions

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

2. Locate the brake lines connected to the brake master cylinder. There is a service tee included in the hookup kit. If the service tee is marked 7914, use the brake line nearest the firewall of the vehicle. If the service tee is marked 7933 use the brake line toward

the front of the master cylinder. Figure 1 shows an installation using the 7933 service tee.

3. Remove the brake line from the master cylinder according to the location described in step 2. Install the

service tee into the master cylinder. Tighten securely. Reinstall the brake line to the end of the service tee as shown in Figure 2. Tighten securely.

4. Install the brake hose to the side port of the service tee as shown in Figure 3. Position the hose fitting to avoid abrasion with surrounding objects. Tighten securely.

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

6. 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 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.

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

8. Figure 4 shows an access hole drilled through the firewall of the vehicle to

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

817-456-8773

BrakeSmart BrakeSmart

Figure 1

Figure 2

Figure 3

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.

9. 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 8 .Figure 4 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.

10. 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. 11. Remove the fuse panel cover from

inside the interior as shown in Figure 5.

12. Install the brake controller power harness to the factory receptacle shown in Figure 6. This area is visible from the where the fuse panel cover was removed in step 10.

13. Route the harness down from this location.

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.

Figure 5

Figure 6

Figure 4

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. Reinstall the fuse cover removed in step 11.

19. 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.

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

21. Close the hood. 22. Stop the engine. 23. Installation complete. 24. Enjoy the many features of your new

brake controller.

Figure 7