trailer brakes

[ricstone]

i have a 2003 windstar with out the tow package. i want to add a electric brake controller for my popup camper. were an how would i wire this up without the factory plug for the controller? any help ? thanks
ric

[phil-l]

ricstone -

I added brakes to my popup camper - and the related wiring to my 2000 Windstar LX 3.8 (no OEM tow package), as well as a tranny cooler and spring airbags.

Some thoughts:

- I highly recommend the Tekonsha Prodigy brake controller.

- I did several wiring projects to add trailer lighting, brake controller and a separate circuit to handle the trailer refrigerator. It pays to spend some time thinking about what you need to do - and how to best accomplish it.

- DO NOT try to use the wires at the brake pedal switch as input to the brake controller on 99+ Windstars, which use low-side switching. My Windstar has a connector tucked *way* up under the dash that has the correct signal for a brake controller. See my pics linked below for details.

- If your Windstar doesn't have the OEM tow package, I highly recommend adding an auxiliary transmission cooler. Having seen both the OEM and aftermarket coolers, I believe the aftermarket does a better job. I got my B&M cooler from Summit Racing and installed it myself. It works fine. More pics below.

- Your stock 'donut' mini-spare is not rated for towing. I swapped over to a full-size spare tire/wheel - and highly recommend this simple upgrade.

- I was worried about rear-end sag, even though my popup camper's tongue weight is fairly low (yes, a weight distributing hitch is a better solution - but I simply didn't have that much weight to deal with). I added AirLift 1000 spring airbags to my Windstar. I've been pleased how much they improve the van's ride when *not* towing. Yet more pics in my links below.


Tranny cooler, wiring and brake controller pics:

http://community.webshots.com/album/549196858rbUAlb


Adding AirLift spring airbags:

http://community.webshots.com/album/548741257AJALLi

Adding popup camper brakes:

http://community.webshots.com/album/548339571fnHjzQ


Further notes on wiring the brake controller:

I make the necessary electrical connections myself. But these folks:

http://www.hitchcorner.com/brake-controls.htm

...carry a wiring adapter for the Windstar. It claims to be only for Windstars with the OEM tow package - but my experience would seem to indicate that all Windstars came with the mating connector. I'd spend some time under the dash of your Windstar; look for the connector I specifically talk about in this picture (from one of the albums above):

http://rides.webshots.com/photo/2882...56340866fmdCMN

[ricstone]

Originally Posted by phil-l

ricstone -

I added brakes to my popup camper - and the related wiring to my 2000 Windstar LX 3.8 (no OEM tow package), as well as a tranny cooler and spring airbags.

Some thoughts:

- I highly recommend the Tekonsha Prodigy brake controller.

- I did several wiring projects to add trailer lighting, brake controller and a separate circuit to handle the trailer refrigerator. It pays to spend some time thinking about what you need to do - and how to best accomplish it.

- DO NOT try to use the wires at the brake pedal switch as input to the brake controller on 99+ Windstars, which use low-side switching. My Windstar has a connector tucked *way* up under the dash that has the correct signal for a brake controller. See my pics linked below for details.

- If your Windstar doesn't have the OEM tow package, I highly recommend adding an auxiliary transmission cooler. Having seen both the OEM and aftermarket coolers, I believe the aftermarket does a better job. I got my B&M cooler from Summit Racing and installed it myself. It works fine. More pics below.

- Your stock 'donut' mini-spare is not rated for towing. I swapped over to a full-size spare tire/wheel - and highly recommend this simple upgrade.

- I was worried about rear-end sag, even though my popup camper's tongue weight is fairly low (yes, a weight distributing hitch is a better solution - but I simply didn't have that much weight to deal with). I added AirLift 1000 spring airbags to my Windstar. I've been pleased how much they improve the van's ride when *not* towing. Yet more pics in my links below.


Tranny cooler, wiring and brake controller pics:

http://community.webshots.com/album/549196858rbUAlb


Adding AirLift spring airbags:

http://community.webshots.com/album/548741257AJALLi

Adding popup camper brakes:

http://community.webshots.com/album/548339571fnHjzQ


Further notes on wiring the brake controller:

I make the necessary electrical connections myself. But these folks:

http://www.hitchcorner.com/brake-controls.htm

...carry a wiring adapter for the Windstar. It claims to be only for Windstars with the OEM tow package - but my experience would seem to indicate that all Windstars came with the mating connector. I'd spend some time under the dash of your Windstar; look for the connector I specifically talk about in this picture (from one of the albums above):

http://rides.webshots.com/photo/2882...56340866fmdCMN

i have been towing with this van for a wile now. i have allready done all of this. from your web pics! but i may be overlooking the break plug but i dont see it. what color is it? thanks
ric

[phil-l]

On my 2000, the plug was taped to the harness, well above the brake pedal. I had to reach *way* up there to get it.

The connector itself is gray - but it was nearly completely covered with black tape when I started.

[ricstone]

Originally Posted by phil-l

On my 2000, the plug was taped to the harness, well above the brake pedal. I had to reach *way* up there to get it.

The connector itself is gray - but it was nearly completely covered with black tape when I started.

thanks phil-l i will look again.
ric