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Trailer Brake Controller Installation - 1999 Sterling L-Line

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How to Install a Trailer Brake Controller on a 1999 Sterling L-Line


Today on this 1999 Sterling L-Line RV, were going to install part number 90195 from Tekonsha, the Prodigy P3 Brake Controller, and also our part number ETBC7 installation kit. Were going to start off by working on the inside of the vehicle and then work our way out. The gray cable that comes with the kit will not be long enough for this install. We end up using a 42-foot length cable to complete the job. This will be part number 10-2-1. Now were going to take our wire, well run it from the inside to the outside.

Theres an existing opening where some wires are ran through, so well go ahead and use that. Well poke the wire all the way through, and leave just enough to do our install inside the vehicle. Next well go ahead and take the remaining wire and were going to route it to our power supply. Now in this case, were going to be using a solenoid thats located inside the vehicle. So well go ahead and route our wire over the steering column, behind the dash, behind the kick plate on the side, and into the junction box located on the side of the vehicle.

Were just going to route it out in front for now to see how it looks. Well take our cable back out and were going to split our cable in half. Well remove the sheath and then split the wire in half. Our black wire will go to the solenoid for a 12-volt power supply going out back to the 7-pole connector. Then our white wire were going to pull back and keep to the side for now.

That will eventually be ran to the blue wire on the 7-pole connector. Then we can go ahead and install our circuit breakers. Well be using two circuit breakers; a 30-amp circuit breaker for our brake controller and a 40-amp circuit breaker for our 12-volt power supply. Well go ahead and mount up the 40-amp circuit breaker first and then the 30-amp circuit breaker alongside. Next well go ahead and run our black wire through the 40-amp circuit breaker.

Well cut the wire in half and well add the ring terminals to each side. Well go ahead and run the end going out to the 7-pole connector to the silver post on the circuit breaker. Then coming off our power supply, well go to the copper end. Now well go over the end of the wire that is closest to our power supply. Well go ahead and put a ring terminal around there, but well leave those connections last. Next well go ahead and run our wiring for the brake controller. Were going to use a length of wire that came from the original ETBC7 kit, and well go ahead and run it to the power supply just like we did with the first wire. However, well split the wire inside the panel, and again, our black wire will go over to the power supply but our white wire will end up going to a ground located inside the panel. Then well go ahead and route our wire through the 30-amp circuit breaker just like we did before. Next well go ahead and work with the wire harness that comes with the brake controller, and well go ahead and put an extension on the red wire. The reason why were going to do this extension is so we can run it to our brake switch, which is located underneath the vehicle. Well also add the buck connectors to the end of the wires as well before we install with the rest of the wires. Going back into the RV, well go ahead and take the red wire and push it through the same hole as our gray cable did. Now well go ahead and hook up our wires that we previously installed. Now our lone white wire will be connected to the blue wire on the brake controller harness. The other two black and white wires that are by the circuit breaker will be matched up color-for-color with the wire harness. Now well go ahead and start working on the brake controller. Well go ahead and mount the bracket for the brake controller underneath the bottom edge of the dash. Well use a couple of self-tapping screws to accomplish this. Then well go ahead and attach the brake controller to the wire harness, and then go ahead and attach the brake controller to the bracket. The brake controller comes with all the hardware needed to attach to the bracket. Now well go ahead and take our wires and zip tie them up and keep them safe and out of the way. Next well go underneath the vehicle and hook up our red wire to the cold side of the brake switch. Then well go ahead and continue on with our gray cable and run it out back towards the bumper. Now well use a variety of fasteners to help hold everything in place. Well add some new zip ties and well add some loom clamps as well. Those loom clamps are part number A0500. Now we can go ahead and install our 7-pole connector. First off, were going to go ahead and find a location on the bumper to go ahead and drill out a hole for our 7-pole connector. Well be using a 2-1/8 inch hole saw. Well drill a pilot hole first, then well go ahead and use our hole saw. Well test fit the 7-pole connector and then go ahead and mark four holes for our bolts to hold the connector in place. Once our holes are marked, well go ahead and remove the 7-pole connector and drill out our holes for our mounting hardware. Now well go ahead and reinstall the 7-pole connector and then the hardware. Well install the screws and the nuts. No well go ahead and start making our connections behind the bumper. First off, well go ahead and hook the 4-pole connector up to the preexisting 4-pole connector behind the bumper. Well also a little bit of dielectric grease and a zip tie to make it a permanent connection. Now well go ahead and hook up our gray cable to the 7-pole connector. Now remember, our black wire will go to the black wire on our connector, and then our white wire will go to the blue connector. Well hook the wires up together with the buck connectors. Well go ahead and run some electrical tape around to seal them up. Then well go ahead and take our ground wire with the ring terminal. Well go ahead and use the self-tapping bolt that comes with it and attach it to the frame. Well take a few minutes to use some zip ties to help secure the wires. Were done with the back of the vehicle, so lets go back up to the front and make our final connections to the power supply. Well take our two black wires, and well go ahead and hook them up to the 12-volt power supply thats constant on the solenoid. Then well go ahead and run our white wire down to the ground. With all our connections made, well take a look at the brake controller. It looks like it has power. Well go ahead and hook up a trailer to it and test it and make sure it works. We can see the little icon of a truck and a trailer there, so we have a connection. Well go ahead and hit the manual override and we can see the numbers go up. Well go ahead and push the brake pedal down and we should get a minimal amount of voltage. So it looks like everything works and its good to go. That will finish it for our install of part number 90195 from Tekonsha, the Prodigy P3 Brake Controller, and also our part number ETBC7 installation kit on our 1999 Sterling L-Line RV.


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