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How to Install a Brake Controller on a 2002 Chevy Express Van

Question:

I have a chevy cut away van/box truck so no sense in buying the standard chevy adapter which plugs into the unit. is there a short pigtail which plugs into the unit...then I can run custom wires from there?

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Expert Reply:

We would be happy to explain how to install a brake controller like # 5100 or # 90885 on your 2002 Chevrolet Express Van but there isn't a pig tail that will fit your van. You will need to hardwire in the brake controller.

If your van came with a factory 7-Way trailer connector the blue output brake wire already ran from the back to the front. It is located under the dash near the emergency brake pedal. But the other 3 brake controller wires will need to be hard wired in.

The white wire grounds to the negative battery terminal. The black wire attaches to the positive battery terminal via a 30 amp circuit breaker # PK54230. The red wire attaches to the cold side of the brake switch.

To find the right brake switch wire you will need a circuit tester # ALL640595 to test each brake switch wire. You need the one that only shows power when the brake pedal is pressed. If a wire also shows power with the headlights or turn signals on it is not the correct wire.

If your van has a round plug with a cap inside the driver's side frame rail instead of a bundle of wires in the jack storage compartment, use part # 30955.

If your van did not come with a factory 7-Way or tow package then you would need to do a complete hard wire. First you would need to install a 4-Way trailer connector # 118377 (unless the van already has one). Then you would need to install 4- and 7-Way installation kit # ETBC7. I have included some links to the right that explains the ETBC7 installation.

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Michael H

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