1. Identify the Wiring:
* Trailer Wiring Harness: Locate the existing 7-way or 4-way trailer wiring harness on your van. It's usually found near the rear of the vehicle, often under the rear bumper or near the taillights. This harness will provide the power and ground you need. You *must* locate the stoplight wire. Incorrectly identifying the wires can lead to malfunction or damage.
* Brake Controller Power Source: The brake controller itself requires power. You'll need a suitable 12V power source, ideally with a fuse for protection. This could be tapped into an existing fuse box circuit (with appropriate gauge wiring and fuse rating), or a dedicated wiring run to the battery. Consult your vehicle's wiring diagrams to identify a suitable circuit. A constant 12V feed is usually necessary.
2. Choose a Brake Controller:
Select a brake controller appropriate for your needs. Consider features like proportional braking, inertia sensing, and user-friendly controls.
3. Wiring Connections (This is where it gets tricky without a wiring diagram):
* Power: Connect the brake controller's power wire to your chosen 12V power source. Use appropriately sized wiring and a fuse.
* Ground: Connect the controller's ground wire to a clean, bare metal surface on the vehicle's chassis, ensuring a good connection.
* Stop Light Wire: This is the *most crucial* connection. You need to tap into the wire that supplies power to your brake lights. This wire will be energized only when the brake pedal is pressed. Use a wire tap or crimp connector to avoid cutting the existing wire. Double-check this wire with a test light before proceeding! Incorrectly identifying it can lead to serious problems.
* Trailer Wiring Harness: The brake controller output wire will connect to the trailer's brake wire on your 7-way or 4-way connector.
4. Mounting the Brake Controller:
Choose a convenient and accessible location to mount the brake controller. This is usually within the driver's reach. Securely mount it to avoid vibration damage.
5. Testing:
* Before connecting to the trailer: Test the brake controller’s operation. There should be an indicator light to show the controller is receiving power, and the braking action should activate when the brake controller is adjusted.
* With the trailer connected: Test the trailer brakes. They should activate smoothly and proportionally with your vehicle's brakes. Start with minimal brake controller gain and gradually increase it to the desired level.
Critical Considerations:
* Wiring Diagrams: Obtaining a wiring diagram for your specific 1998 Ford E-150 conversion van is crucial. This will greatly simplify the process and help you identify the correct wires. You can often find these online (search for "1998 Ford E-150 wiring diagram") or from a Ford dealership.
* Professional Installation: If you're not comfortable working with vehicle wiring, it's best to have a professional install the brake controller. Improper wiring can cause electrical problems or even safety hazards.
* Fuse Protection: Always use appropriately sized fuses to protect your wiring and the brake controller.
* Trailer Brakes: Ensure that your trailer brakes are in good working order.
This is a general overview. The specifics will vary depending on your van's setup. Consult your vehicle's wiring diagram and the brake controller's installation instructions before beginning this work. If you're unsure at any point, seek professional assistance.
