FORD F250
BrakeSmart Controller Custom Install

After reading many comments and reviews, primarily on RV.NET, I decided to purchase a BrakeSmart Controller. It seemed to get the best ratings and considering the price of the 5th wheel we'd be towing it just didn't make sense to me to buy anything but the best, just to save $200. After receiving the unit I decided to install the controller in the dash pocket since they were similarly shaped. I thought others might also be interested in a custom install so I took a few pictures and notes as I went along.

A word of CAUTION: This installation requires partial disassembly of your dash and drilling several holes into the BrakeSmart Controller case which probably will void your controller warranty, or worse, could destroy the controller if you're not careful. I tried to think of ways to attach it without drilling holes (duct tape, brackets, etc) but couldn't think of anything that would be 100% solid. These notes are for reference only as your situation may be different. I take zero responsibility if something goes wrong. Use at your own risk.

I installed the pressure hose and sensor per their instructions. Since I have an automatic I routed the wiring thru the firewall plug where the clutch would be with a standard transmission.

You must first remove the dash component that contains the pocket. Mine was attached with (10) 7mm screws. Remove the litter bag holder (2 screws). Reach in and disconnect the wiring harness from the lighter then pop out the lighter base (it might be easier to pop the base out first). Remove the cup holder (2 screws on the sides, 2 screws inside on the top). Remove 2 screws along the bottom of the component.

Now comes the tricky part. There are still 2 screws holding the top of the component. They are underneath the overlapping dash component. Carefully pull on the right side of the overlapping component then along the bottom toward the steering wheel. Just pull it far enough away to get a 7mm socket underneath to remove the 2 remaining screws. I tried pulling mine further away but it didn't seem to want to give so I decided not to force it. Be careful not to scratch the pocket compartment. The pocket component has a small tit on the top, right side that rests inside a hole. It should now lift out.

The pocket now needs to be cut off. I included a picture indicating the approximate size of the cutoff piece. I used a small saw at first but went to a Dremel. You'll find that the sides of the pocket are where the controller case touches as you get closer to a fit; the top and bottom will fit easily. Don't take too much off at first; better to make several cuts then to take off too much.

Remove the 4 screws from the back of the controller case and you'll see some areas on the inside where mounting screws can protrude without touching any internal components. Unfortunately I was too involved during this stage and forgot to take pictures of the inside. The drivers side is pretty straight forward. On the passengers side I inserted a screw in the small area above the red, manual brake switch. I couldn't get the drill inside to drill a hole below the switch. I used #6 x 1/2" sheet metal screws.

Now all you have to do is put it all back together. Here's some final shots.