PART No: PRODUCT: BRAKE CONTROLER HARNESS MAKE & MODEL: FORD RANGER - MAZDA BT-50 INSTALLATION INSTRUCTIONS

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2 1. In the engine bay, locate the vehicle battery jumper (1). 2. Route the power input harness (2) from the battery (1) towards the LHS of the firewall. Note: Do not connect the power input harness to the battery at this point. 3. Locate the ORANGE power female terminal (1) and the WHITE ground female terminal (2) to the locations as shown on the 2-way connector (3). 4. House the power & ground input harness female terminals (1 & 2) into the mating connector (3). 5. Connect the power input harness connector (3) to the body harness mating connector, an audible click can be heard when correctly installed TERM COLOUR FUNCTION 1 ORANGE POWER 2 WHITE GROUND 6. Route the electric brake controller wire end of the Body (1) towards the LHS firewall grommet. 7. Route the other end of the Body (1) down towards the vehicle undercarriage. Page 2

3 8. Locate the LHS firewall grommet (1), 9. Cut the tip off one of the grommet nipples (2) and route the four electric brake controller wires (3) through and into the vehicle cabin. 10. Following the diagram below, house the brake controller power harness terminals (1) to the corresponding slot on the connector (2). 11. Insert the secondary lock (3) into the connector (2). Connect the brake controller power harness connector to the brake controller output harness. 12. Following the diagram, house the brake controller power harness terminals (1) to the corresponding slot on the connector (2). 13. Insert the secondary lock (3) into the connector (2). Connect the brake controller power harness connector to the brake controller output harness TERM COLOUR FUNCTION A ORANGE / WHITE POWER B RED BRAKE INPUT C WHITE GROUND D BLUE ELECTRIC BRAKE OUTPUT D C B A A B C D Page 3

4 14. Route the Body (1) down towards the vehicle undercarriage. 15. From underneath the vehicle, locate the power harness (1). 16. Route the power harness (1) along the hydraulic lines and the LHS chassis rail, following the existing vehicle harness towards the rear of the vehicle and up towards the vehicle harness tail light connectors. Note: When routing any harnesses under the vehicle, ensure to avoid all moving parts, sources of heat or sharp objects. Also ensure harness is secured with cable ties every 200mm. Mazda BT-50 shown. Also applies to Ford Ranger. 1 For 7-Pin Smart Click (can be identified by a blue patch connector on the trailer harness), go to Step 17. For non Smart Click, go to Step 18. Page 4

5 17. Disconnect and discard the female blue 8-way tail patch connector containing the 'brakes signal' and 'electric brakes' labels. Connect the brake controller harness 8-way connector to the towbar wiring harness mating connector. Connect the brake output harness 8-way connector to the tail harness 8-way mating connector. Push the connectors in until a click is heard. Go to Step 19. Note: Sedan-type vehicle shown for illustrative purposes. ECU Towbar Wiring Discard the patch if not required. 7 pin Trailer Socket Brakes Output 18. At the rear of the vehicle, source the brakes signal and electric brakes from the towbar wiring harness and splice the appropriate wires together as marked on the patch harness. Note: Sedan-type vehicle shown for illustrative purposes. Brakes Output ECU Towbar Wiring 7-pin Trailer Socket 19. Connect the body harness (1) ORANGE/WHITE wire (2) to the positive terminal on the vehicle battery (3). 20. Connect the body harness (1) WHITE wire (4) to the negative terminal on the vehicle battery (3). 21. Secure the brake controller harness with cable ties (not supplied) away from any moving parts, sharp edges or hot surfaces at 200mm intervals. Page 5

6 22. Test the body harness using a light board or multimeter. 23. Secure the brake controller harness with cable ties (not supplied) away from any moving parts, sharp edges or hot surfaces at 200mm intervals. 24. Re-fit all removed parts and secure all fasteners, ensuring there are no squeaks or rattles. 25. Place the instructions in the glove box after fitment. Page 7