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Troubleshooting Intermittent Brake Controller Functioning

Question:

I have 7 inch brakes on my pop up and just received Dexter replacement magnets from trailer. The are the same shape and size as the old magnets and the parts included match. To insure the brakes stayed equal I replaced the magnet on both wheels and reassembled. Hooked up the trailer. The green light on the brake controller came on when I started the vehicle but then went out when I put it in gear. I unplugged and plugged in again the electric harness into the connection, returned to the vehicle and the green light was once again on. I then did the initial setup with the brake controller put dial at maximum setting, put pressure on foot brake pedal, red light comes on, roll back until it turns to orange, release pedal, turn dial to 12 oclock position. The drive several hundred feet to level road, brought the speed up to 25 mph. With slide on controller, I started to apply the trailer brakes. Heres where the problem happened, Just after I started to slide the trailer brake the light went out on the controller. This is not supposed to happen. I continued to slide the brake lever on the controller to see if the brakes would work but there was no response from the trailer brakes. The light stayed off when the slide was released and stayed off until I returned home 5 minutes later, backed the trailer into the driveway and shut the vehicle off. When I turned the vehicle off the green light came on on the controller and stayed on even when the ignition key was removed! I had to unhook the hitch to get the light to go out. I checked all wire connectors for a loose wire and found none. I checked the wires connections for accuracy and everything was wired as it had been on the old magnets. Whats wrong?

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Expert Reply:

Most likely the problem is corrosion in your trailer connector. Dirty pins in a connector are notorious for causing intermittent circuit function which is exactly what is going on with your setup.

Aside from that it could be a loose wire on the brake output circuit somewhere, but it sounds like you already checked that.

It could also be a loose power or ground wire for the brake controller (which based on your description sounds like a Tekonsha Voyager part # 39510).

I attached an FAQ article on brake controller installs for you to check out as well.

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Jameson C

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