Trail Rocker Installation Instructions

Transcription

1 Trail Rocker Installation Instructions Manual #90580 For Installing Painless Part Numbers: and Painless Performance Products recommends you, the installer, read this installation manual from front to back before installing this harness. 1

2 Perfect Performance Products, LLC Painless Performance Products Division 2501 Ludelle St. Fort Worth, TX PHONE: FAX: If you have any questions concerning the installation of this harness, feel free to call Painless Performance Products' Tech Line at The Tech Line can be reached from 8 A.M. to 5 P.M. central time, Monday through Thursday, and 8 A.M. to 4:30 P.M. on Fridays. We have attempted to provide you with as accurate of instructions as possible and are always concerned about corrections or improvements that can be made. If you have found any issues or omissions, or simply have comments or suggestions concerning these instructions, please write us at the above address, send us a fax at (817) , or us at painless@painlessperformance.com. We sincerely appreciate your business. Perfect Performance Products, LLC shall in no event be liable in contract or tort (including negligence) for special, indirect, incidental, or consequential damages, such as but not limited to, loss of property damage, or any other damages, costs or expenses which might be claimed as the result of the use or failure of the goods sold hereby, except only the cost of repair or replacement. 2

3 CONTENTS Refer to the Contents Figure (below) to take inventory. See that you have everything you re intended to have in this kit. If you find that anything is missing or damaged, please contact the dealer where you obtained the kit or Painless Performance at (800) The Painless Trail Rocker Kits and should contain the following: Relay Center pre-installed to powder coated bracket. 200 Amp midi fuse Switch Panel with 5 pre-installed switches Ignition power splice and weather-pack connector. Parts Kits: (12) un-insulated butt connectors, (12) pre-cut head shrink, (3) Adel Connectors, (3) ¼ 20 Stainless Bolts, (3) ¼ nylon locking nuts, (2) ¼ stainless nuts, (2) lock washers, (2) flat washers, (1) rubber grommet This manual (90580) SMALL PARTS Included with the Painless harness are parts kits containing miscellaneous terminals, fuses, screws, and nuts. Many of the terminals are non-insulated and will require heat shrink to be applied after the terminal has been properly crimped. Heat shrink has been supplied. 3

4 These non-insulated terminals allow you to keep a cleaner, more traditional look; colored insulated terminals would seem out of place. When crimping these terminals, take notice to the split in the terminal. Make sure the smooth side of the jaw on the crimper goes towards this split. TOOLS NEEDED In addition to your regular hand tools, you will need, at least, the following tools: Stripping Tools: A good set of wire strippers are required to strip wire properly. This style of wire stripper is ideal for this harness install because of its ability to properly strip wire gauges 10 to 20.These are available from just about any local auto parts store, electrical supply shop, home improvement store or can be purchased online. Volt/Ohm Meter: A Volt/Ohm meter is always a good tool to have on hand when installing any type of electrical components into any vehicle. Most basic units provide the two functions required to diagnose electrical issues seen during a harness install. These two functions are the ability to read DC Voltage and electrical continuity or Ohms. They can be purchased from any home improvement store, local hardware store and electrical supply shop and online. Heat Gun: Very useful to shrink the heat-shrink found in the parts kit. Basic Hand Tools For tightening the relay center bracket, etc. 4

5 INSTALLATION Beginning on the Page 7 is a picture by picture, step by step installation guide for installing your new Trail Rocker. These steps MUST be followed as they are printed. Do not move onto other parts of the installation out of sequence. 5

6 BEFORE BEGINNING INSTALLATION Before removing the negative terminal on the battery, you will need to: Set Parking Brake Turn key to RUN position Place shift lever into D position Pull 4 wheel drive lever into 4L position CAUTION: BEFORE THE INSTALLATION OF THIS PRODUCT, DISCONNECT THE POWER FROM YOUR VEHICLE BY REMOVING THE NEGATIVE BATTERY CABLE FROM THE BATTERY. THE BATTERY SHOULD NOT TO BE RECONNECTED UNTIL INSTRUCTED 6

7 Step 1: Using a 10mm socket, loosen and remove the negative battery cable from the battery. 7

8 Step 2: Using wire cutters, cut loose the two Umbrella Style Zip Ties on top of the battery tray. 8

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10 Step 3: Position Adel clamp over the factory wiring harness. Step 4: Mount Adel clamp to inside wall of factory battery tray using supplied ¼ 20 Bolt, flat washer, and ¼ nylon locking nut. 10

11 Step 5: Using 10mm wrench or socket, remove factory battery tray mounting nut from the stud on the firewall. (For ease of installation, we recommend removing factory engine cover) 11

12 Step 6: Position Trail Rocker relay center mounting bracket over the factory firewall mounted stud. 12

13 Step 7: Position Adel clamps over the Trail Rocker wiring harness. 13

14 Step 8: Using provided (2) ¼ 20 bolts, (2) flat washers, and (2) nylon locking nuts, mount the Relay Center bracket to the factory battery tray as shown. 14

15 Step 9: Using a 10mm wrench or socket, reinstall factory battery tray nut to stud on firewall. 15

16 Step 10: Route Trail Rocker control wires across the firewall. Secure the control wires to the factory harness loom using provided zip ties. You can now reinstall your engine cover. Step 11: On the driver side of the engine bay, locate the horn and remove it using a 10mm wrench or socket. 16

17 Step 12: With the horn removed, you can now access the pass-through on the firewall. This is your access point to route the control wires into the interior. (Note: You may need to push open the factory carpet using your finger) 17

18 Step 13: Carefully route the white control wire connector through the pass-through. Step 14: Apply provided rubber grommet over control wires with the slit facing up. 18

19 Step 15: Push/apply grommet into firewall access hole as shown. 19

20 Step 16: We will now move to the interior of the vehicle. In order to install the switch panel, you will need to reposition the center console. To do this, you need to pull up on it. (There are no screws or bolts, only retainer clips.) 20

21 Step 17: With the center console positioned back, you will now remove the netted storage panel from the dash by using a pry tool, or carefully pulling on the netting. 21

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23 Step 18: With the old panel removed, you will now install the Trail Rocker switch panel. First you will need to route the control wire plug as shown below. 23

24 Step 19: With the control wires routed and pulled through, you will now position and clip in the new Trail Rocker switch panel. Press down firmly to ensure the panel locks in place at the bottom. 24

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26 IF YOU WANT TO OPERATE YOUR SWITCHES WITH A CONSTANT POWER (AS SHIPPED), YOU WILL SKIP STEPS THESE STEPS ILLUSTRATE HOW TO HOOK UP YOUR TRAIL ROCKER TO IGNITION SWITCHED POWER. Step 20: You will now remove the panel below the steering column by carefully pulling from the top first. 26

27 Step 21: With the plastic panel out of place, you will now use a 10mm socket or wrench to remove the two bolts holding the metal bracket in place. 27

28 Step 22: You will now locate the ignition switch connector and remove it. Using a small flathead screwdriver, unlock the orange locking clip. 28

29 Step 23: With the locking clip unlocked, you will squeeze the bottom of the connector and remove it by pulling it down. Step 24: You will now peel back the convoluted tubing covering the wires running to the ignition switch connector and cut the Pink/White Ignition 12V wire about 2 inches from the connector. 29

30 Step 25: Now it is time to unpin your factory ignition switched 12V wire. To do this, you will first use a small screwdriver or pick to remove the blue locking mechanism. 30

31 Step 26: With the blue lock removed, you will now use a small pick or screwdriver to depress the lock underneath the middle terminal. (Pin 3 = Ignition Switched 12V) 31

32 Step 27: With the terminal unlocked, you will now pull the terminal out of the connector. 32

33 Provided in your parts kit is a replacement Pink/White wire that will provide your Trail Rocker with ignition switched power while allowing you to terminate into the factory ignition switched 12V wire. 33

34 Step 28: You will now re-pin the factory ignition switch connector (Pin #3) with the supplied ignition switch wire. Step 29: With the ignition switch wire fastened, you will now reinstall the blue locking mechanism. 34

35 Step 30: You will now strip the factory pink/white 22 gauge wire 3/8 an inch. Once stripped, you will fold the copper wire in half, ensuring a tight connection into the butt connector. Once stripped, you will now crimp the factory wire into the open end of the butt connector on the provided Trail Rocker ignition wire. (NOTE: make sure the heat shrink is installed before crimping). 35

36 Step 31: After crimping, you will now slide the heat shrink over the connection. Using a heat source, heat the heat shrink ensuring a tight wrap around the connector. Step 32: Reinstall the factory convoluted tubing over the Trail Rocker ignition switched 12V wire and factory wires. 36

37 Step 33: Reinstall the factory ignition switch connector. Step 34: You will now connect the weather pack connector from the ignition switched 12V to the white control wire plug. 37

38 Step 35: Connect the white control wire plug to the switch panel plug. Once connected, apply zip ties to factory wiring. 38

39 Step 36: Reinstall metal bracket and plastic panel. 39

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41 Step 37: OUTPUT WIRE ROUTING. As there are many accessories available that the Trail Rocker can control, there are no specific pictures of output wire installation. You will route these wires to the location of your components. Ensure to route safely, avoiding high heat areas, moving parts, and sharp edges. It is suggested to use grommets for any wires passing through metal to avoid wearing through the wire insulation and causing arcing. Make sure any accessories and components you install are properly grounded. 41

42 Output Wire Color Diagram: Switch #1: Grey/White Switch #2: Blue Switch #3: Yellow/White Switch #4: Orange Switch #5: Blue/Yellow Switch #6: Purple Extra output wires: Output #7: Pink Output #8: Green 42

43 OPTIONAL: If you are wanting to use the two extra Output Wires (#7 Pink and #8 Green), they will need to be wired into the existing switches. Pages will provide a step-by-step tutorial on achieving this. Provided in the kit are (2) dual blade connector terminals, shown below. 43

44 Once you choose the switch you want to have control the extra output, you will disconnect the female terminal of the existing wire (from the male terminal on the bottom of the switch) and double up with the extra Output Wire using one of the provided dual blade connector 44

45 After pressing the extra Output Wire onto the dual blade terminal, you will press on the female terminal of the original wire you removed from the switch. Once both wires are installed onto the dual blade connector, you will then slide it onto the terminal on the switch you initially removed the control wire from. 45

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47 Step 38: After wiring in your components to the output wiring, you may now reconnect the negative terminal of your battery. 47

48 Step 39: With the battery connected, you can now test out and enjoy your new Trail Rocker! 48

49 NOTES 49

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51 Painless Performance Limited Warranty and Return Policy Chassis harnesses, fuel injection harnesses, Trail Rocker and Striker ColdShot units are covered under a lifetime warranty. All other products manufactured and/or sold by Painless Performance are warranted to the original purchaser to be free from defects in material and workmanship under normal use. Painless Performance will repair or replace defective products without charge during the first 12 months from the purchase date. No products will be considered for warranty without a copy of the purchase receipt showing the sellers name, address and date of purchase. You must return the product to the dealer you purchased it from to initiate warranty procedures. 51

52 Painless Performance Products LLC 2501 Ludelle Street Fort Worth, TX Phone (817)