'05 Factory Brake Controller Question

[PineKnot]

Truck (see sig) has a factory controller. I have recently acquired both a 16' box trailer and a 12.5K equipment/car hauler, both new. Both have Dexter torsion axles with brakes on all wheels. My question is this: With the controller at max (10) I have what I would consider adequate braking loaded for normal conditions with both. Loaded panic stop I'm not so sure, but that's an unknown so far. Hard test stops with both trailers empty will not lock any wheels. What should I expect and how should I evaluate what I have? I'd be more comfortable if I were in the adjustment range somewhere rather than maxed out to begin with.
I seem to remember discussion of low controller output voltage on the '05, but attempts at search here came up with nothing.
As you can see I don't have a lot of experience in this area, and any help would be appreciated.

[mdmasters]

I would start with making sure the drum brakes on both trailers are adjusted. I had a similar issue till I adjusted the spacer on the brake shoes on the 5er, now the setting on the controller is 6.5 and not 9.5.

The GN triple torsion axle trailer runs about 6.0 loaded from new.

[PineKnot]

Thanks, I'll check that out even though both trailers are new.
Anybody else have a thought?

[firesoutmatt]

Yes Install a new P3 and run a seperate plug for the trailer brakes . You can remove the factory controller which the P3 will plug into the same harness but you will have to go back to a dealer and have them reprogram the puter for no factory controller. If not it will give a trailer disconnect message every time you start the truck.

The other thing you can do is buy a Factory 06 MY controller and swap them out.

I am or was in the same boat as you. The early 05's seem to have not very good controllers.

[CAMPINGTOM]

I have heard that the early 05 brake controllers do not work at speeds under 5 mph. Makes it hard to do a pull test or slide the sliding hitch back. This appears to be the case with mine. Can anyone confirm this?

[Black05]

Tom -- My 05 IBC was this way. There was minimal voltage unti lyou were at 15 mph or more. I convinced Ford to replace it with the later version that came in mid 05. The new one works fine.

[Lightningfast01]

The pre March 05 controller does not apply FULL power under 15mph. The thought behind this was to make backing and slow maneuvering easier. Trucks made after March 05 have the revised controller and apply full power at all times. You could jack up the axle and roll the wheels at 20mph or so to trick the controller possibly. Then you could test the brake pin on the 7 pin connector for voltage output. It should be @ 12VDC max on 10 setting. The controller varies the output voltage from 1-12V though the 0-10 controller settings. I have an old 10/04 2005 F250 controller and it applies my 28ft trailer brakes fine. I have never gone over 6.5 setting without excessive braking for 12K lbs. I have not skidded tires though I never wanted to do that.

[PineKnot]

Thanks for that information. That low voltage output at low speeds may be what had me fooled. Also, at other posters' suggestion I found the brakes on my new trailers WAY out of adjustment to start with. Got caught again assuming that the factory would take care of such things, or the dealer prep (Insert appropriate laughter here).
Chances are everything with the controller is okay after all. I'm going to rig up to check my at speed voltage just to be sure.

[Lightningfast01]

I can bump mine manually a low speeds and feel nothing. I bump them at 40 or 50mph and they are nice and crisp. You have to adjust the drums on trailers...

[CAMPINGTOM]

<div class="ubbcode-block"><div class="ubbcode-header">Originally Posted By: Black05</div><div class="ubbcode-body">Tom -- My 05 IBC was this way. There was minimal voltage unti lyou were at 15 mph or more. I convinced Ford to replace it with the later version that came in mid 05. The new one works fine. </div></div>
Black05, thanks for the heads up. I'm going to try to get Ford to replace mine. What did you say to convince them and who did you talk to? My dealer isn't being very helpful.

[Black05]

Tom -- I explained to them that when I haul hay (28' Flat bed gooseneck), I have dirt road hills to climb; and that if I had to stop for traffic or road conditions and back down, the trailer would drag the truck down the hills and jack knife. It was a safety issue for me. I started with my service advisor and, when progress seemed stalled, I then asked that they get the regional rep involved. They were very nice and with a little pushing were accomodating. I have read where some forum members have had success and others have not. Good luck.

[CAMPINGTOM]

Thanks for the information. I'll let you know how it goes.