FI11409 - TPWKIT-001 - Ford Ranger and Everest

FI11409 - TPWKIT-001 - Ford Ranger and Everest
FORD RANGER / EVEREST
KitPart
PartNo:
No:XXXXXXXXXX
TPWKIT-001
Kit
Fitting Time: 60 minutes
Tow-Pro Wiring Kit - Ford Ranger / Everest
Kit Part No: TPWKIT-001
Accessory Kit
Estimated Fitting Time: 90 Minutes
FI11409
Page 01 of 17
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Issue: 1 Date: 01/02/2017
FORD RANGER / EVEREST
Kit Part No: TPWKIT-001
General Notes
• Read through the fitting instructions before installation of the accessory. Install the accessory following the fitting
instructions. Failure to do so may cause damage to the vehicle or the accessory.
• Ensure all recyclables, discarded vehicle accessory components and packaging are recycled following local recycling
regulations.
• It is always recommend that this accessory is fitted by a qualified automotive Technician.
• Safely store and protect any removed vehicle components.
• Ensure all bare metal surfaces are protected using automotive bare metal primer and touch-up paint, or suitable
automotive rust inhibitor.
• Remove all metals swarf and dust from all vehicle surface if surfaces is used for accessory installation.
Safety Notes
• Check that all work practices comply with safety standards.
• Please wear appropriate clothing and use safety equipment.
Parts Supplied
B
A
Electric Brake Harness x1
G
C
Brake Controller Bracket
x1
Heatshrink x1
M4 Nyloc Nut x4
E
J
M5x16mm Thread Cutting
Screw x2
F
K
M5 Flat Washer x2
900mm Cable Ties x15
200mm Cable Ties x15
Cat 5 Cable x1
Butt Splice x1
I
H
M4 Flat Washer x4
D
L
Push Clip Cable Tie x1
Switch Template
(Page 17) x1
M
Fitting Instruction x1
FI11409
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FORD RANGER / EVEREST
Kit Part No: TPWKIT-001
Tools Required
Phillips Head Screw Driver
Ratchet
Socket Set
Side Cutters
Electric Drill
Step Drill
Drill Bit Set
Trim Removal Tool
Crimper
Utility Knife
Soldering Iron
Heat Gun
T25 Torx Head
Screw Driver
FI11409
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FORD RANGER / EVEREST
Kit Part No: TPWKIT-001
Wiring Diagram
Extra routing for
Ford Everest routing only.
FI11409
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FORD RANGER / EVEREST
Kit Part No: TPWKIT-001
Step 1
Important
Always refer to the vehicle’s Workshop Manual when
removing vehicle components.
• Note down all clock and radio settings.
• In the engine bay, disconnect the negative battery terminal.
• Remove the LHS front scuff plate (1) and dislodge the LHS front
rubber door seal (2).
1
2
Step 2
• Remove the rear LHS scuff plate (1).
• Dislodge the rear LHS rubber door seal (2).
1
2
Step 3
• Dislodge and remove the LHS B-pillar trim (1).
1
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FORD RANGER / EVEREST
Kit Part No: TPWKIT-001
Step 4
• Remove the LHS kick panel (1).
1
Step 5
• Squeeze both sides of the glove box compartment (1) and swing
the drawer downwards towards the footwell.
• On each corner of the glove box compartment (1), pull the
drawer towards the seat to dislodge the hinges.
1
Step 6
• Remove the RHS center consol trim (1).
1
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Kit Part No: TPWKIT-001
Step 7
• Remove the LHS center consol trim (1).
1
Step 8
• Remove the two bolts (1) on either side of the center console
accessory trim (2).
2
• Dislodge the center console accessory trim (2) and disconnect
any connectors behind it before removing from vehicle.
1
2
2
1
Step 9
• Dislodge the gear shift surround trim (1) and disconnect any
connectors behind it before removing from vehicle.
1
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FORD RANGER / EVEREST
Kit Part No: TPWKIT-001
Step 10
• Cut out and adhere the appropriate supplied Switch Template
(1) (Page 17) to the gear shift surrounding trim (2), ensuring to
align them to the vehicle trim edges as indicated.
2
• Using a Ø2mm drill bit, drill out the pilot hole in the locations
specified on the template (1).
• Drill out the top hole to Ø3.5mm and the bottom hole to Ø10mm.
• Remove any plastic ribs interfering with the hole from behind.
1
Ranger - Low Spec
Everest
Ranger - Hi Spec
Step 11
• Plug the Cat 5 Cable (1) supplied in the wiring kit, into the remote
head (2) and fit the remote head to the gear shift surrounding trim
(3).
• Secure the remote head to the surround trim (3) as shown. Torque
the nut (4)to 0.8 Nm.
1
• Rotate the shaft (5) fully anti-clockwise and fit the knob (6) to the
shaft (5) with “0" pointing upwards as shown below.
5
• Route the Cat 5 Cable (1) towards the glove box area.
5
3
1
2
6
5
6
4
Step 12
4-way ECU
connector
• Secure the Brake Controller ECU (1) onto the Brake Controller
Bracket (2) using the supplied M4 Flat Washers (3) and M4 Nyloc
Nuts (4).
4
3
• Ensure the ECU orientation is correct, as shown.
• Attach the supplied Push Clip Cable Tie (5) to the Brake Controller
Bracket (2) as shown.
1
2
5
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Cat 5
cable
Issue: 1 Date: 01/02/2017
FORD RANGER / EVEREST
Kit Part No: TPWKIT-001
Step 13
• Connect the 4-Way connector (1) from the Electric Brake Harness
to the Brake Controller ECU (2).
1
• Connect the supplied Cat 5 Cable (3) to the Brake Controller ECU
(2).
2
• Route the Cat 5 Cable (3) back onto the Brake Controller Bracket
(4) and secure using the Push Clip Cable Tie (5) as shown.
4
3
5
Step 14
If the vehicle is a Ford Everest, proceed to Step 15.
If the vehicle is a Ford Ranger, continue:
4
• Locate the two holes (1) on the inner LHS of the glove box
compartment area.
• Secure the Brake Controller bracket assembly (2) to the vehicle
chassis using the supplied M5 Washers (3) and Thread Cutting
Screws (4) as shown. Ensure not to over tighten.
3
2
Proceed to step 16.
1
1
Step 15
If the vehicle is a Ford Ranger, refer to Step 14.
If the vehicle is a Ford Everest, continue:
• Locate and remove the two torx bolts on the inner LHS of the
glove box compartment area.
• Secure the Brake Controller Bracket assembly (1) to the vehicle
chassis using the two previously removed vehicle torx bolts (2) as
shown.
2
Proceed to step 16.
1
2
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FORD RANGER / EVEREST
Kit Part No: TPWKIT-001
Step 16
• Secure the ground ring terminal (1) from the Electric Brake
Harness to the vehicle earth point (2) using the existing fastener
(3).
1
2
3
Step 17
• Inside the cabin, route the Electric Brake Harness Red Wire
terminals (1) towards the driver’s brake pedal area.
• Secure using the supplied Cable Ties and ensuring the wire does
not interfere with any moving parts.
1
Step 18
• Disconnect the brake switch connector (1).
1
• Once disconnected, identify which connector is used.
PX1 Ranger vehicles will be a 2-way connector (2).
PX2 Ranger\Everest vehicles will be a 4-way connector (3).
2-Way Connector
4-Way Connector
2
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3
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FORD RANGER / EVEREST
Kit Part No: TPWKIT-001
Step 19
For all models excluding PX2 Ranger XL Plus, continue with step 19.
For PX2 Ranger XL Plus models, go to step 20.
4-Way Connector
• Select the appropriate patch from the two supplied in the wiring
harness kit.
1
• If required, release the secondary locks on the supplied patch
connectors before housing the terminals.
• House the RED female terminal (1) into the female connector
empty cavity (2).
3
2
4
2-Way Connector
• House the RED male terminal (3) into the male connector empty
cavity (4).
1
3
• Ensure the secondary locks are re-engaged after inserting the
terminals.
2
2-Way Connector
2
1
Front view female connector
4
4-Way Connector
4
1
Front view female connector
Proceed to Step 21.
Step 20
For PX2 Ranger XL Plus models only.
4-Way Connector
• On the 4-way Connector Patch (1) locate the grey wire (2) on Pin
1.
1
• Carefully de-house the GREY wire male (3) and female (4)
terminals.
• House the GREY wire male (3) and female (4) terminals into the
pin 4 location.
• House the RED female (5) and male (6) terminals into pin 1
location.
• Ensure secondary locks are re-engaged after inserting the
terminals.
4-Way Connector
3
2
4
3
6
4-Way Connector
4
2
4
5
1
Grey White Black
Red
Front view female connector
Proceed to Step 21.
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FORD RANGER / EVEREST
Kit Part No: TPWKIT-001
Step 21
• Connect the patch (1) created in Step 19/20 between the brake
switch (2) and brake switch connector (3).
1
• Secure using the supplied Cable Ties.
2
1
3
Step 22
• Lift the front passenger side carpet (1) and remove the LHS
vehicle blanking grommet (2).
1
2
2
Step 23
• Route the Electric Brake Harness blue wire and Circuit Breaker (1)
through the vehicle grommet hole (2) and seat the harness
grommet (3) to the vehicle.
2
Important
Ensure the Harness Grommet is seated correctly to
prevent any water ingress.
1
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FORD RANGER / EVEREST
Kit Part No: TPWKIT-001
Step 24
• Route the Electric Brake Harness blue wire (1) along the top of the
chassis rail towards the rear of the vehicle.
3
3
• Route the Electric Brake Harness circuit breaker (2) along the top
of the chassis rail towards the front of the vehicle.
1
• Secure Harness using supplied 900mm Cable Ties (3).
3
2
Step 25
If the vehicle is a Ford Everest, proceed to Step 27.
If the vehicle is a Ford Ranger, continue:
• On the LHS rear tub area, locate the OE Harness 16-way
connector (1) and disconnect.
• On the male connector, peel the back of the PVC tape to expose
the blue wire (2).
1
• Locate the White Tape (3) on the Electric Brake Harness (blue
wire), cut at this point and discard the extra length.
• Strip 5mm of insulation from both the Electric Brake Harness (blue
wire) and the vehicle blue wire.
• Route the Electric Brake Harness (blue wire) to this area.
3
2
Step 26
• Slip the supplied Heatshrink over the wire and insert both blue
wires into the supplied Butt Splice.
1
2
3
4
Keep heatshrink away from joint until after soldering is
complete and cooled.
• Crimp both wires to the Butt Splice using indent type crimpers.
• Solder the wires to the Butt Splice. Ensure that a good connection
is made.
• Wait for the Butt Splice to cool, slip the Heatshrink over the joint
and heat.
• Reconnect the 16-way connector (1).
Proceed to Step 30.
1
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FORD RANGER / EVEREST
Kit Part No: TPWKIT-001
Step 27
If the vehicle is a Ford Ranger, refer to Step 25.
If the vehicle is a Ford Everest, continue:
• Continue routing the Electric Brake Harness blue wire (1) around
the rear of the vehicle towards the RHS rear wheel area.
• Secure Harness using supplied Cable Ties along the top of the
towbar and vehicle harnesses.
1
Step 28
• On the RHS rear wheel area near the exhaust hanger, locate the
OE Harness 16-way connector (1) and disconnect.
• On the male connector, peel the back of the PVC tape to expose
the blue wire (2). The blue wire (2) may be up to 300mm away.
1
• Strip 5mm of insulation from both the Electric Brake Harness (blue
wire) and the vehicle blue wire.
• Route the Electric Brake Harness (blue wire) to this area.
5mm
2
Step 29
• Slip the supplied Heatshrink over the wire and insert both blue
wires into the supplied Butt Splice.
1
2
3
4
Keep heatshrink away from joint until after soldering is
complete and cooled.
• Crimp both wires to the Butt Splice using indent type crimpers.
• Solder the wires to the Butt Splice. Ensure that a good connection
is made.
• Wait for the Butt Splice to cool, slip the Heatshrink over the joint
and heat.
• Reconnect the 16-way connector (1).
1
Proceed to Step 30.
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FORD RANGER / EVEREST
Kit Part No: TPWKIT-001
Step 30
• Route the positive ring terminal (1) from the Electric Brake Harness
(2) along the chassis rail towards the engine bay.
6
• Secure with the supplied 900mm Cable Ties.
• In the engine bay, fasten the positive Electric Brake Harness ring
terminal (1) to the vehicle positive post (3) located behind the
fuse box.
5
2
• Secure the Circuit Breaker (4) onto the vehicle bracket as shown.
• Fasten the negative Electric Brake Harness ring terminal (5) to the
vehicle ground location (6).
• Secure the Electric Brake Harness (2) in the engine bay using the
supplied 200mm Cable Ties.
3
1
4
Step 31
• Reconnect the engine bay negative battery terminal.
• Test the operation of the Electric Brake Harness using a test lamp
or a multimeter to ensure correct operation.
• Dispose of any parts not used from the fitment.
Important
Secure all harnesses to the vehicle using cable ties.
Refit all removed parts and secure all fasteners to the
Service Manual torque specifications.
Important
Reprogram all radio stations and clock settings by
referring to the vehicle's Owner's Manual.
Please place the Fitting Instructions and Owner's
Manual in the glove box after installation is completed.
E. & O.E. This document is copyright and must not be used except as permitted below or under the Copyright Act 1968. You may reproduce
and publish this document in whole or in part for your or your organisation's own personal or internal compliance, educational or noncommercial purposes. You must not alter or amend this document in any way. You must not reproduce or publish this document for
commercial gain without the prior written consent of the copyright owner.
FI11409
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Issue: 1 Date: 01/02/2017
FORD RANGER / EVEREST
Kit Part No: TPWKIT-001
FI11409
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Issue: 1 Date: 01/02/2017
FORD RANGER / EVEREST
Kit Part No: TPWKIT-001
Electric Brake Switch Template
Template
50mm
50mm
Ford Ranger Low
Spec EBC Switch
Ø3.5mm
Ø10mm
Important
Always confirm the length of the 50mm scale markers
before drilling.
Ø3.5mm
Ø3.5mm
Ø10mm
Ø10mm
Ford Ranger Hi
Spec EBC Switch
Ford Everest
EBC Switch
FI11409
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Issue: 1 Date: 01/02/2017
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