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How to Install a Brake Controller in an 03 Dodge Ram

A Dodge Ram is a full-size pickup truck that Chrysler has manufactured under its Dodge brand since 1981. The 2003 model belongs to the third generation of this series, which was in production from 2002 to 2008. The anti-lock braking system in a 2003 Dodge Ram has a brake controller known as a hydraulic control unit, or HCU. The HCU prevents the wheels from locking during an emergency stop by reducing the braking power to a wheel when it rotates more slowly than the other wheels.

Instructions

1

Disconnect the housing for the left front turn signal with a socket wrench and remove the extension panel under the housing. Detach the electrical connector for the horn and disconnect the horns access cover.

2

Disconnect the mounting screws for the windshield washer reservoir and pull the reservoir up. Detach the electrical connector and hose from the windshield washer pump. Disconnect the reservoir and remove it from the engine compartment.

3

Remove the cables from the battery with a socket wrench and disconnect the power distribution center in the engine compartment. Push the connectors for the electrical wiring harness together to detach it from the controller anti-lock brakes. Disconnect the brake lines from the HCU.

4

Disconnect the front mounting bolt for the HCU bracket through the access opening with a socket wrench. Disconnect the rear mounting bolt for the HCU bracket from the engine compartment. Pull the HCU assembly up slightly and detach it from its bracket.

5

Place the new HCU in its mounting bracket, and install the HCU assembly. Tighten the mounting bolts for the HCU bracket to 11 foot-pounds with a torque wrench. Connect the brake lines to the HCU and tighten its retaining nuts 115 inch-pounds. Attach the wiring harness for the controller anti-lock brakes and lock the connectors into place.

6

Install the reservoir for the windshield washer. Connect the motor and hose for the windshield washer pump. Fasten the mounting screws for the reservoir with a socket wrench.

7

Attach the battery cables and the power distribution center. Connect the electrical connector for the horn, and replace the horns access cover. Fasten the extension panel and housing for the left front turn signal.

Posted by Unknown at 5:15 PM

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