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Troubleshooting Intermittent Disc Brake Function on 2009 Chevy 2500HD with Titan BrakeRite

Question:

I have a 5th Wheel equipped with Titan BrakeRite electric over hydraulic actuators and disc brakes. When I bought a used 2009 Chevy 2400HD with Factory Brake Controller, a DX35FR was added to the 5th for compatibility. My issue is sometimes the brakes dont function at all. I see the Trailer Brake bars changing on the dashboard, but I can definitely feel the 5th push the truck. When this happens, there is no response when I use the manual activator, but the dash bars do work. Other times, everything works as it should, but I need them to work 100 of the time. My question is two part. #1 - where would I start looking for why the factory system is failing me? #2 - I have a Tekonsha 90195 P3 Electronic Brake Controller from my old truck I want to wire to a separate 7-pin plug as a back-up. What do I need to do since the 5th has a DX35FR attached to the braking electrics? its mounted right next to the Titan Hydraulic unit

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Expert Reply:

It sounds like the issue is the factory controller, which I've seen a lot of our neighbors replace altogether on many older Chevy, GMC and Ford trucks; however, the issue could also be on the brake output wire coming from the controller to the 7 way trailer connector on your 2009 Chevy Silverado. I recommend starting by cleaning off the 7 way plug on the trailer and vehicle to make sure it's clean and free from debris or corrosion, as the connection issue could be caused by that. You'll also want to test the brake output wire for any damage; you'll want to check the wiring on both the trailer and the the vehicle's 7 way wiring for any cut or damaged that might be making contact with the frame. If you can let me know what you find there, I'm happy to help you continue to troubleshoot this issue.

With that said, I'm not aware of a solution for adding a brake controller that's wired to a completely 7 way and honestly, the best solution here is just to swap over to your Tekonsha P3 # 90195 for full time use in your 2009 Chevy Silverado. You will need to disconnect the factory integrated brake controller, which is outlined in a helpful article we put together that I've attached to this answer; you can simply disconnect the # DX35FR adapter you've installed to the Titan BrakeRite and you'll be ready to use it with your P3.

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