Things You'll Need:
- Bully Brake Turbo-charged diesel engine Pliers Drill Screwdriver Electronic meter/test lamp
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Step 1
Find a work area that you can put the truck that is well lit and is within easy reach of the tools you will use. Lift the hood of the truck and open the doors. Disconnect the battery from the electrical system. Loosen and remove the red battery cable from its post or side-mounted location and tie back the cable in a safe place where it will not become loose and fall back into place, causing a short in the truck's electric circuit.
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Step 2
Secure the Bully Brake controller to the underside of the dashboard near the driver's right knee. This position allows for easy access to the extra braking when needed. Use self-tapping screws to attach the controller-mounting bracket to the underside of the dash. Mount the controller on the bracket and stretch out the wiring in the direction it will follow to the junctions that will be made with the existing electrical system.
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Step 3
Drill a hole in the firewall to send the positive side of the wiring to the battery junction box. Unless the wire is able to be passed through an existing harness opening in the firewall, you will have to create a hole for this wire to travel through. Use silicon to fill in the hole when finished to create a watertight seal from the outside. After the hole has been drilled, feed the length of positive power wire out through the engine compartment. Use tie wraps to secure the wiring along other existing wire paths and out of the way of any moving parts or heat.
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Step 4
Connect the positive wiring to the junction box using a fuse tap that has at least a 30-amp fuse in the slot. It is important not to allow too much power into the controller or the braking power may become erratic. A 30-amp fuse will break the circuit before any damage can occur when the system cannot avoid a surge in power due to a short circuit somewhere else in the electrical wiring of the truck. Insert the two junction box brake fuses supplied with the kit. These will help regulate the proper braking during use and protect the rest of the system from electrical damage.
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Step 5
Find the brake light switch wire located at the top back of the brake pedal. Use a pointed test lamp to stab each wire located in the adapter. When you find the one that lights the test lamp when the brake pedal is pressed, use a snap wire splice to connect the brake switch of the controller. Each time the brake is pressed, the controller will activate the warm-up valve of the turbo to decrease the engine's compression, slowing the vehicle dramatically. Connect the short male and female adapter included with the kit from the brake to the controller wire harness to complete the under-the-hood connections.
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Step 6
Tap the brake activation wire into the turbo warm-up valve by using the test lamp to find which brake wire lights the test lamp upon starting the engine. This brake wire powers the warm-up valve, which keeps the turbo passage closed while the engine warms after starting the engine. Activating this valve during braking will cut the amount of air going in and out of the engine, which reduces compression and slows the vehicle down. Use a T splice snap adapter to make this connection. Finish the job by securing a good ground wire to the frame and connecting the battery cable back to its original secure position on the battery.
