Join Date: Feb 2013
Feedback Score: 0 reviews
Factory Brake Controller Issue
I did some searching around, but I didn't find any definitive answer to my question, so I hope someone here can answer it or post a link to a thread I missed. Or maybe even know a place where I can get it repaired and save myself some money ($300 for a new controller).
2006 F350 6.0L factory brake controller. Shows no faults--actually appears to be working, but my wife told me to check the trailer brakes (brand new installed last year) because she said they didn't feel like they were engaging. She hauls a two horse goose neck trailer, and she's been hauling horses for over 15 years, so I trust when she says something doesn't feel right. Anyway, The bars scroll across the bottom when you push on the brake pedal and everything, but the brakes don't engage. We pulled the trailer up on the ramps, I spun two of the tires, and she hit the brakes. Nothing but a slight hum from the magnets in the brakes. I spun the wheels again and she hit the manual override and the wheels locked right up as expected, and a very noticeable and louder hum was heard.
If I understand how these controllers are hooked up, I believe the brake pedal sends a signal to the controller, which is then amplified and sent to the plugs on the back of the truck. Correct? She has a plug tester that has LEDs for every function of the 7 pin plug. When you use the brake pedal, sometimes the brake LED flashes and goes out or stays on, but it's really dim. With the manual bypass it's as bright as the other LEDs (left and right tail lights, 12V, etc).
So, I believe I have it narrowed down to the controller itself. I even took the lower dash apart partially to look at the wiring to check for anything loose, broken, worn, etc. I'm ex-Navy nuke electrician and now an Electrical Engineering Technician, so I'm quite familiar with electrical troubleshooting, but I wanted to get your guys' input on this matter. I'm good at what I do, but I may have missed something. Oh, and we did check all fuses associated with the brakes and controller. We have a print out of all the fuses and anything that had "brake" in it, we checked.
Thanks in advance for your help.