Painless 57002 Instructions Manual Download Page 7

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FUSE/RELAY CENTER INSTALLATION

The following steps MUST be followed as they are printed. Do not move
onto other parts of the installation out of sequence.

CAUTION: BEFORE THE INSTALLATION OF THIS PRODUCT,

DISCONNECT THE POWER FROM YOUR VEHICLE BY REMOVING THE
BATTERY CABLES FROM THE BATTERY. THE BATTERY SHOULD NOT TO
BE RECONNECTED UNTIL INSTRUCTED

Step 1: Use a

10mm wrench

socket

to loosen and remove the

battery cables from the battery. For ease of installation, we also
recommend removing factory engine cover.

Summary of Contents for 57002

Page 1: ...7 2010 Jeep Wrangler JK Dash Panel Trail Rocker For Installing Painless Part Number 57002 Manual 90581 Painless Performance Products recommends you the installer read this installation manual from fro...

Page 2: ......

Page 3: ...instructions please call or email us our contact information can be found at the top of this page or online at www painlessperformance com We sincerely appreciate your business Painless Performance Pr...

Page 4: ...SWITCH PANEL INSTALLATION 26 SWITCH WIRING 27 DOUBLING SWITCH CONTROL WIRES 29 IGNITION SWITCH PIGTAIL INSTALLATION 41 RELAY OUTPUT WIRES 45 OPTIONAL PAINLESS PART 57150 WINCH CONTROL ADD ON KIT 49 O...

Page 5: ...sulated butt connectors 10 pre cut heat shrink 8 insulated wire caps 3 piggyback terminal 4 30 amp ATO fuses 1 200 amp MIDI fuse 1 M6 1 0 nut 1 M6 lock washer and 1 M6 flat washer Power and Ground Ter...

Page 6: ...7 Hand Crimpers 8 Cable Cutters 9 Cable Crimping Tool 10 Hammer In addition to these basic hand tools you may need the following Volt Ohm Meter A Volt Ohm meter is always a good tool to have on hand w...

Page 7: ...AUTION BEFORE THE INSTALLATION OF THIS PRODUCT DISCONNECT THE POWER FROM YOUR VEHICLE BY REMOVING THE BATTERY CABLES FROM THE BATTERY THE BATTERY SHOULD NOT TO BE RECONNECTED UNTIL INSTRUCTED Step 1 U...

Page 8: ...2 Use a flathead screwdriver to lightly pry the factory wiring and connector from the right side of the battery box Then remove the black plastic retainers so that the connector is easy to stow away...

Page 9: ...5 Step 3 After you remove the connector unlock the red tab by using a flathead screwdriver...

Page 10: ...6 Step 4 With the tab unlocked unplug the connector Step 5 Use a 10mm wrench or socket to remove the battery tray mounting nut from the stud on the firewall...

Page 11: ...Locate the Fuse Relay Center in your new Remove and discard the black plastic retainers and flat washers securing the Fuse Relay Center to its packaging The retainers and washers are NOT used in inst...

Page 12: ...move the Fuse Relay Center from the bracket To do this remove the lid from the Fuse Relay Center using a 7 16 wrench or socket Step 8 Once the cover is removed notice the mounting bolts located below...

Page 13: ...9 Step 9 Use a 2 Stubby Philips head screwdriver to hold the bolts in place while you remove the threaded acorns nuts on the bottom of the unit with a 7 16 wrench or socket...

Page 14: ...10 Step 10 With the Fuse Relay Center removed locate the center hole on the bracket and a 20 stainless bolt Insert the bolt into the center hole...

Page 15: ...11 Step 11 Fasten the bracket to the Fuse Relay Center using the threaded acorns nuts you removed in Step 7...

Page 16: ...12 Step 12 Position the Fuse Relay Center mounting bracket over the factory firewall mounted stud and hand tighten the factory battery tray nut onto the firewall stud...

Page 17: ...13 Step 13 Use the provided 1 20 bolts 1 flat washers and 1 nylon locking nuts to mount the Fuse Relay Center mounting bracket to the factory battery tray as shown...

Page 18: ...14 Step 14 Use a 10mm wrench or socket to reinstall the factory battery tray nut to stud on the firewall and secure the Fuse Relay Center mounting bracket...

Page 19: ...Position 2 1 Adel clamp over the Fuse Relay Center control wires Step 16 Mount the Adel clamps to the holes on the Fuse Relay Center bracket using the supplied 2 20 bolts 2 flat washers and 2 nylon lo...

Page 20: ...ewall Secure the control wires to the factory harness loom using the provided zip ties Remember also to reconnect the factory connector you unplugged in Steps 2 4 Step 18 On the driver side of the eng...

Page 21: ...itch Control wires with a piece of masking tape This step is necessary to insure ease when feeding the wire through the firewall on Step 21 Failing to tape the ends can cause the loose wires to catch...

Page 22: ...18 Step 21 Carefully route the Switch Control wire connector through the pass through Step 22 Apply the provided rubber grommet over the Switch Control wires with the slit facing up...

Page 23: ...ess hole as shown Step 24 On the interior remove the tape and locate the 12 pin connector shell in your parts kit Then connect the pinned wires from the Fuse Relay Center using the diagram below NOTE...

Page 24: ...20 Now move to Step 25 on page 21 for the Switch Panel installation...

Page 25: ...center console To do this first remove the 4 bolts holding the console in place using a T30 Torx driver All the bolts run along the base of the console with 2 accessible from the front seat and the ot...

Page 26: ...22 Step 26 Next remove the netted storage panel from the dash by using a pry tool or carefully pulling on the netting...

Page 27: ...23 Step 27 Remove the original metal retainer clips from the panel you just removed and attach them to your Trail Rocker Switch Panel...

Page 28: ...24 Step 28 Now install the Trail Rocker switch panel by routing the control wire plug through the center console as shown below...

Page 29: ...Step 29 With the control wires routed through position and clip in the new Trail Rocker switch panel Press down firmly to ensure the panel locks in place at the bottom Finally reattach the center cons...

Page 30: ...26 SWITCH WIRING The lighted rocker switches included in your kit are wired as shown in the diagram below...

Page 31: ...ovided in the kit are several piggyback terminals like those shown below These terminals provide you with two different options for doubling switch control wires Step 30 Choose which switch you want t...

Page 32: ...28 Step 31 Place on the piggyback terminal Step 32 Take the power output wire and an additional wire from the Switch Control pigtail and connect them to the piggyback terminal...

Page 33: ...WANT TO OPERATE YOUR SWITCHES WITH A CONSTANT POWER AS SHIPPED SKIP STEPS 33 50 AND MOVE ON TO THE RELAY OUTPUT WIRES SECTION ON PAGE 41 Step 33 Remove the panel below the steering column by carefully...

Page 34: ...30 Step 35 Locate the ignition switch connector and remove it To do this use a small flathead screwdriver to unlock the orange clip on the side of the connector...

Page 35: ...locked squeeze the bottom of the connector and disconnect it Step 37 Now peel back the convoluted tubing covering the wires running to the ignition switch connector Then cut the Pink White 12V ignitio...

Page 36: ...32 Step 38 Unpin the factory ignition switched 12V wire To do this first use a small screwdriver or pick to remove the blue locking mechanism...

Page 37: ...33 Step 39 With the blue lock removed use a small screwdriver or pick to depress the lock underneath the middle terminal Pin 3 Ignition Switched 12V...

Page 38: ...ull the terminal out of the connector Provided in your parts kit is a replacement ignition pigtail that will provide your Trail Rocker with ignition switched power while allowing you to terminate into...

Page 39: ...5 Step 41 Remove the driver side dash access panel and insert the new ignition pigtail thru the channel to the center access and route the ignition pigtail towards the factory ignition switch connecto...

Page 40: ...36 Step 42 Now re pin the factory ignition switch connector Pin 3 with the new ignition pigtail Step 43 With the ignition pigtail fastened reinstall the blue locking mechanism...

Page 41: ...nector Then slide a piece of heat shrink over the factory wire and crimp it into the open end of the butt connector on the ignition pigtail NOTE make sure the heat shrink is installed before crimping...

Page 42: ...38 Step 46 Reinstall the factory convoluted tubing over the factory wire Step 47 Reinstall the factory ignition switch connector and lock it into place...

Page 43: ...Relay Center Note for ease of installation you may want to unplug the Fuse Relay Center s switch control wire connector from the Switch Control Panel Step 49 If you do disconnect the Switch Control Pa...

Page 44: ...40 Step 50 Reinstall the driver side access panel and then replace the metal bracket and plastic access panel beneath steering column...

Page 45: ...output wires to most accessories Relay Output Wire Color Diagram Switch 1 Grey White Switch 2 Blue Switch 3 Yellow White Switch 4 Orange Switch 5 Blue Yellow Switch 6 Purple Extra Relay Output wires W...

Page 46: ...Step 51 Locate the relay output wire from the Fuse Relay Center you wish to use Then locate the input wire on the accessory you are installing Step 52 Double up the accessory s input wire if necessar...

Page 47: ...e of heat shrink from the included parts kit over the accessory wire Then use an un insulated butt connector to crimp together the accessory wire with the relay output wire Step 54 Secure the heat shr...

Page 48: ...44 Step 55 Cap all unused relay output wires by crimping on the provided insulated wire caps Then store the extra wires out of the way in the most convenient way possible...

Page 49: ...n and out functions of a winch when it is installed These control wires can be connected to a winch switch not provided in the kit If you do not have a winch switch Painless offers a Winch Control Add...

Page 50: ...ires from the switch you are replacing with the Winch Control Add on Kit Then locate the tabs located at the top and bottom of the switch Step 57 These tabs lock the switch in place To remove the swit...

Page 51: ...58 Insert the Winch Control Add on Kit into the empty socket of the bracket Step 59 Before connecting the wires to the Winch Control Add on Kit take time to familiarize yourself with the wiring diagra...

Page 52: ...48 Step 60 Reconnect the power ground and control wires to the Winch Control Add on Kit as seen below...

Page 53: ...ch pigtail included in your parts kit Then locate the winch connector on your Fuse Relay Center Step 62 Remove the cap from the winch connector on the Fuse Relay Center Then plug in the winch pigtail...

Page 54: ...revious installation steps you may now reconnect your battery terminals Locate the 6 gauge unterminated red cable coming from the Fuse Relay Center heat shrink and the appropriate sized for your parti...

Page 55: ...ength you need to route the cable to the positive terminal Cut and strip the wire about Step 65 Once the cable is stripped remove it from the Fuse Relay Center in order to crimp on the included ring t...

Page 56: ...mping tools can be found at your local parts store or online Once the terminal is crimped secure it with about 1 of heat shrink Step 67 Next re install the cable and 200 amp MIDI fuse to the Fuse Rela...

Page 57: ...Step 68 Locate 1 black heat shrink and 1 16 14 ga non insulated ring terminal Strip the wire about and slide the heat shrink over it Step 69 Crimp on the ring terminal and secure it with the heat shri...

Page 58: ...he terminals back up to your battery Connect the red cable to the positive terminal and the ground wire to the negative terminal Step 71 With the battery connected you can now test out and enjoy your...

Page 59: ...200 amp midi fuse is located on the fuse block on the side of the Fuse Relay Center mounting bracket The Fuse Relay Center contains eight 30 amp ATO fuses and can be accessed by removing the lid from...

Page 60: ...56 Trail Rocker Fuse Centers are equipped with 8 Indicator Fuses These fuses are equipped with an LED light that will turns on when the fuse is blown thus indicating when the fuse needs to be replaced...

Page 61: ...e original purchaser to be free from defects in material and workmanship under normal use Painless Performance will repair or replace defective products without charge during the first 12 months from...

Page 62: ...Painless Performance Products LLC 2501 Ludelle Street Fort Worth TX 76105 Phone 817 244 6212...

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