Trailer Brakes Seem Weak After Installing Prodigy Brake Controller on 2001 Ford Excursion  

Expert Reply:

You may need to adjust the boost level on the Prodigy controller so that it starts out at a higher voltage output when you step on the brakes. If you believe that the controller is not putting out enough voltage you can test the output at the trailer connector with the trailer disconnected.

What you will do is first set the controller to the maximum output. Then use a meter such as # PT89ZR to test the brake output pin while someone sits in the vehicle and fully applies the manual override. You should be seeing at least 12 volts.

Then you can connect the trailer and test again at the power wire that goes to the magnets. A drop of more than a couple of volts would indicate a problem somewhere between the controller and where you find the drop. Inspect the wiring and fix as needed. Also make sure the vehicle and trailer side connectors are clean and free of corrosion inside and out.

If the full voltage is getting to the magnets then make sure the magnet ground wires are attached to clean and corrosion free bare metal surfaces. And if you still have weak brakes and they are adjusted as you said then it could be the magnets themselves.

For magnets you can visually inspect them and if you see any copper windings coming through they will need to be replaced. To further test the magnets you can follow the procedures in the help article I have linked for you.