How to Install the Hopkins Trailer Brake Controller on a 2009 Ford E-350

Question:

I purchased a Penske truck from the fleet sales. It has a ball and 4 pin already installed. Of course my trailers are all 7 pin. I like the idea of a brake controller and the HM47297 b/c the room at right knee has limited clearance already. Im likely to have plug in under dash b/c of the exiting 4 way, correct? Where will I find it? Will I have to make changes under the dash to plug in the break controller b/c of the prewire for the 4 pin? What is the best way to convert from 4pin to round?

asked by: Barry

Expert Reply:

If your Penske truck was built on a Ford E-350 chassis then it is possible that it does have a plug to plug in a brake controller, though additional components will be needed to complete the installation.

You will need to check behind an access panel on the center of the dash but more on the passenger side. Pry the panel off gently. The connector should be behind this panel. If so then you would use brake controller wiring harness # HM47855 for use with Insight controller.

Since your vantruck has a 4-Way flat connector, the blue wire on the harness that plugs into the truck will need to be cut off just before the end that plugs into the truck. You will then need to run wire from this blue wire, under the truck, all the way to the back where the 4-Way is. You can use wire # 12-1-1 sold in 1 foot increments.

With the brake controller plugged in and mounted according to the instructions the next step is adding the 7-Way. You will need connector # 37185. The 4-Way will plug into this adapter. There will be 4 wires left to hardwire. The white ground will attach to the metal frame. Purple is for reverse lights and would connect to a reverse light wire behind a tail light. If reverse lights are not needed you can tape up this wire and stow it out of the way.

Blue will go to the blue wire you ran from the brake controller. So that just leaves the black wire. The black wire is for 12 volt power. If none of your trailers use 12 volt power you can tape this wire up as well. If it is needed you will again need wire # 12-1-1 and a 40 amp circuit breaker # PK54540.

Attach one end of wire to the black wire then route the other end under the truck and up through the engine compartment to the battery. Avoid areas that can pinch or burn the wire when routing it. Under the hood, mount the circuit breaker to the metal of the engine compartment. The black wire you ran will go first to the AUX post on the breaker. Then attach another length of wire from the BAT post on the breaker to the positive battery terminal to complete installation.