Trailer Brake Controller Installation - 1994 Chevrolet C/K Series Pickup

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How to Install a Trailer Brake Controller on a 1994 Chevrolet C/K Series Pickup


Today on our 1994 Chevy Pickup, we'll be installing the Curt Triflex Brake Controller, part number C51140. This will be in conjunction with the etrailer Brake Controller Install Kit, part number ETBC7. We'll plug in our trailer and we'll have a CC showing that our trailer wiring is connected, then we can press on the brake pedal and watch the numbers increase. We can also use the hand sweep to energize our trailer braking. Once we remove our trailer wiring from the 7-Pole connector, we'll get a DC for disconnected. To start, we'll first go ahead and assemble the 7-Pole adapter bracket.

With the hardware provided, we'll use it to attach the bracket to the 7-Pole adapter. We'll go ahead and take the bracket, feed it over the wires, and up to the back of the mounting surface for the 7-Pole adapter. Then we'll take the screws, feed them through the front side of the 7-Pole, and secure it with the nuts on the back side. Once we have all 4 in place, we'll go ahead and tighten them down. I'm going to go ahead and take some black electrical tape and wrap up 8 to 10" of our wire. This will assist in bundling our wires together and help protect it from the elements.

Now we can go ahead and take the 7-Pole bracket and attach to the hitch bracket. Once we've secured the 7-Pole to the hitch bracket, we'll now go ahead and take the 4-Pole connector coming out of the back of the 7-Pole connector and attach it to the 4-Pole connector already installed on the vehicle. Note it's recommended to use some of the Edelman dielectric grease, part number 11755, between these 2 connection points to help keep them free from dirt, dust, debris, and especially moisture and preventing corrosion. Then we'll take the gray duplex cable from our install kit, strip it back, and attach it to the 2 butt connectors coming out of the back of our 7-Pole connector. We'll connect black to black and white to blue. The black wire will be the 12-volt hot supply to our 7-Pole connector and the blue wire is for trailer braking.

We'll go ahead and wrap it up with some black electrical tape to bundle up our wires, clean up our install, and keep it free from dirt, dust, debris, or moisture. We'll go ahead and run the wire along the top of the hitch and over to the frame. Once we secure the wire, we'll then take the white wire with the pre-attached ring terminal and the self tapping screw provided with our install kit and secure it to the frame, providing a ground for our 4 and 7-Pole connector. Then we'll go ahead and take the gray duplex cable and follow the frame up into the engine compartment and ultimately to the battery. Keep in mind when routing your wires, stay away from any moving components such as steering or suspension, or excessive heat such as exhaust. We'll use the black zip ties provided with our install kit to secure it as we go.

We'll need to find a grommet bushing or make and install a bushing to route our wire into the cabin of the vehicle through the firewall. Because we don't have any manufacturer's accessible grommet or bushing to go through, we'll go ahead and install the Spectro Snap Bushing, part number SWC8057. First, we'll go ahead and drill a pilot hole and verify that we have plenty of room to install the Snap Bushing. Once we've got our pilot hole drilled, we'll go ahead and use a step fit process, using larger sizes to get to our final size of 11/16ths. Once we've drilled our final size, we'll go ahead and install the Snap Bushing into the firewall. Once it's in place, we'll then go ahead, mark our gray duplex cable where it will go through the fire wall, split the gray duplex cable, so that the white wire can run inside the cabin of the vehicle and the black wire will route across the top of the fire wall, over to the passenger's side and near the battery. We're going to go ahead and route a power and ground wire for our Brake Controller. For this application, we'll need to add an extra length of wire, so we'll use the ETBCXW Kit for an additional 10' of the jacketed gray duplex cable. We'll go ahead and route it through our Snap Bushing into the cabin of the vehicle. We'll go ahead and move inside the cabin of the vehicle. We'll install the Curt Triflex Brake Controller. Now, with our Curt Brake Controller mounted and secured, we'll go ahead and install the Curt Universal Wiring Adapter, part number C51515. Then we'll go ahead and route the wire underneath the dash, towards the brake switch, so we'll follow the wiring down until it goes into the wiring harness where it's easily accessible. We can remove the black electrical tape and then use our test light to find the wire that is hot only when the brake pedal is depressed. With our key on and our test light ready, we'll go ahead and test the yellow wire coming out of our brake switch. This will be our hot only when the brake pedal is depressed. Now, to connect that to the red wire from our Brake Controller pigtail we'll use the quick splice connector provided with our install kit. We'll slide the quick splice connector over the yellow wire and into position and then slide the red wire into the connector and crimp it down. We can then close the clasp and we'll wrap it up with some black electrical tape to help bundle our wires back up and keep it free from dirt, dust, debris, and moisture. Then we'll go ahead and take the 3 remaining wires coming from our Brake Controller pigtail, strip them back, and add the yellow butt connectors provided with our install kit. We'll start making our connection. We'll take the white wire we ran through the fire wall into the cabin of the vehicle that came from our 7-Pole connector and attach it to the blue wire from our Brake Controller pigtail, providing the power for trailer braking. Then we'll go ahead and take the gray duplex cable, strip back several inches of sheathing, and then the black and white wire. We'll then match color for color, black to black, white to white, for our Brake Controller pigtail, providing power and ground for the Brake Controller. Once our connection is made, we'll once again go ahead and wrap them up with some black electrical tape. Now we'll go ahead and secure our wiring as necessary underneath the dash and then we'll cut off the excess from the zip ties to clean up our install look. Now we'll move back into the engine compartment. We'll take the black power wire that we ran from our 7-Pole connector and the gray duplex cable we just ran to the Brake Controller pigtail, route them across the top of the fire wall, securing them and running them over to passenger's side inner fender well. As we route our wiring, we're also going to use several of the Redline Metal Loom Clamp, part number A0500, to help secure our wiring. Now we'll go ahead and leave our wires. We need to install the 2 breakers, 1 for our 7-Pole connector and 1 for the Brake Controller. We'll first install the 40 amp breaker for our 7-Pole connector. We'll use the self-tapping screws provided with our install kit. Then we'll install the 30 amp breaker for our Brake Controller. Now with the breakers installed, we'll start connecting our wires. We'll take the black wire from our 7-Pole connector, cut it to length, strip it back, and add a small ring terminal. We'll then install the small ring terminal onto the silver side of the breaker, securing it with a star washer and nut. Next, we'll take the gray duplex cable, cut it to length, strip it back, and add a small ring terminal to the black wire, and a large ring terminal to the white wire. The black wire will go to the silver side of the 30 amp breaker and the white wire will get routed to the negative battery terminal in most cases. However, because there is a side post mounted battery, it can be difficult to add the ring terminals directly to the negative battery terminal, so for this application, we can use a manufacturer's ground located right next to the battery. We'll need to run 2 hot leads from the copper side of each breaker to the positive battery terminal. To secure them to the positive battery terminal, we'll be adding the Deka Battery Side Bolt Extender, part number DW05416. To do that, we'll remove the positive battery terminal from the battery. Then we'll go ahead and take the post out of the battery cable. Once we remove the old post, we can go ahead and install the new one and then reconnect it to the battery. We'll remove the nut from the extended portion of the stud, and then go ahead and create our leads going from the copper side of the breaker to the positive battery terminal with the leftover black wire from our gray duplex cable. To do that we'll strip back 2 ends and add 2 small ring terminals. We'll connect those to the breaker and then route it over to the positive battery terminal. We'll cut the wire in half, strip back both sides and add 2 large ring terminals, install the ring terminals onto the battery post extender, and secure them. Once we've secured these wires, we can go ahead and cut off the excess from the zip ties to clean up our install look here in the engine bay and that does it for the install of the Curt Triflex Trailer Brake Controller, part number C51140 in conjunction with the etrailer Brake Controller Install Kit, part number ETBC7, on our 1994 Chevy Pickup. .


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