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Thursday, February 6, 2014

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

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.

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.

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.

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.

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.

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.

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.

Sunday, October 6, 2013

How to Hook Up the Brake Controller on the 2006 Duramax

Duramax is the name of an 8-cylinder 6.6-liter diesel engine that General Motors has manufactured since 2001. The 2006 version carries the LLY designation and is an option for many full-size Chevrolet pickup trucks. The braking system on vehicles with a 2006 Duramax engine includes an electronic brake control module. The function of the EBCM is to keep the wheels from locking during an emergency stop by applying less braking force to a wheel that is rotating more slowly than the other wheels.

Instructions

Remove the negative battery cable with a socket wrench to prevent anyone from inadvertently starting the engine. Raise the vehicle with a floor jack and support it on jack stands. Clean the area around the EBCM under the vehicle with a shop cloth to prevent contamination of the disassembled braking components.

Disconnect the mounting screws for the EBCM with a socket wrench and discard the mounting screws. Pull the EBCM down slightly to detach it from the brake pressure modulator valve, or BPMV. Discard the EBCM.

Clean the mounting surfaces on the BPMV with a clean shop cloth to ensure a good electrical contact between the EBCM and BPMV. Install the new EBCM to the BPMV with new mounting screws and fasten the mounting screws with a socket wrench.

Lower the vehicle with the floor jack. Attach the negative battery cable with a socket wrench.

Turn the ignition on. Connect a scan tool to the data link connector under the dashboard on the left side of the steering column. Check and clear any error codes that the scan tool displays.