[wpetko]

Greetings, TDS Friends!
The '05 in my sig has had a problem with the factory brake controller for some time. It is VERY weak, even with the gain turned up to 10.0. My 5th wheel brakes are fine. The 5th wheel was hooked up to the shop truck at my RV dealer & they had no problem locking up the trailer brakes in their lot. I had the controller module replaced 6 months ago (nearly $700.00) & it seemed a little better, but now I'm not so sure. I know these things are suppose to be proportional, but I can't get them to do more than just slow the rig down a little even at highway speed using the manual switch. On top of that, I'm thinking about getting a new truck soon and an RVing friend of mine really wants to buy this truck from me. I can't do this to him knowing how dangerous this could be & I really want this completely resolved before anyone else hooks up & tries to tow with this thing.
The truck is going into the shop for an oil change soon & I will ask them to check this out again while it's there. Do any of you know the secret to these early factory brake controllers? Would a later year model control module be the solution? Does anyone else have the same problem? How about those of you with a later year model?
Thanks in advance for your help on this.
Warren

 

[outlawdiesel]

My '05 Lariat does the exact same thing. To get any stopping power going down a grade etc I have to use the manual switch. It sits on 10 all the time and just doesn't feel like it is turned up nearly far enough to apply any pressure.

I hate to bypass the factory dash unit, but I am wondering if an aftermarket under the dash box might be in order.

PS: I did replace the pressure switch on the brake pedal about a year ago which helped out a bit, but still not very good braking power at all. It was malfunctioning to some degree...the brake lights still worked but would not turn off the cruise control and applied even less trailer braking than it does now.

 

[jimmy]

Has the brake pressure sensor on master cylinder been checked?
Ford IDS can check the sensor for response as pedal pressure goes up and so can an AutoEnginutiy scan tool.
The brake pressure sensor is a vital input to proportion trailer brake level.
Turning up the number sets the current scale for the brakes but the pressure sensor is the input that will make control vary across that scale.

 

[wpetko]

Well, here's an update on my problem. I took the truck to the shop at the dealership to have things checked out again (for another $129.00). They checked the module, pressure switch & the sensor on the master cylender (or so they say). All checked out OK. I then took my 5th wheel to the RV dealer's shop for an unrelated repair & asked them to hook it to the shop truck & see how the brakes work. When hitched to the shop truck the trailer brakes can be made to lock up & skid on the gravel parking lot. Obviously, the problem still lies with my truck. I was told to read page 172 of my owner's manual for directions on setting the gain. Essentially it says that you have to be hitched up & moving at 25 - 30 mph to set gain. I did that & still no better. 'Any more ideas out there?

 

[TBS-POPS]

have someone check the voltage output at the controller head and the trailer plug when the brakes are applied.should be the same or could be a bad wire with too much resistance. also check to be sure the ground wire is good too. makes a huge difference. check connections inside trailer plug!!!

 

[wpetko]

TBS-POPS,
'A little clarification please where is the controller head? Is it on the truck or the trailer? Please be as detailed as possible and thanks so much for your help.

 

[PerryB]

A few years ago there were numerous complaints about the early IBC units doing just what you describe. The common fix was to install a control unit for an '06-up vehicle. The early units were programmed to reduce output below about 20 mph and generated a lot of complaints.

 

[wpetko]

A few years ago there were numerous complaints about the early IBC units doing just what you describe. The common fix was to install a control unit for an '06-up vehicle. The early units were programmed to reduce output below about 20 mph and generated a lot of complaints.

Thanks, PerryB. I've heard the same thing myself. Last September when I took the truck to the shop for this problem they told be that the control unit had gone bad & needed to be replaced ($700.00). I told them to please replace it with a unit from an '06 or later. I don't think they did & I'm about to go to war with them over this, but I need some more ammunition.
I really need to hear from some of you '06 & later owners. Does your factory brake controller work well & can you lock up your trailer brakes at low speed just like an aftermarket unit? I really need to know this so that I can have a well informed argument.
Thanks in advance for your help.

 

[goldrush]

i have an 08 and it will lock the brakes at 0 mph. my dad has an 05 and you have to be going 20 mph to get his to work. my truck will output 10 plus volts sitting still, his will only output 2.8 sitting still.

 

[PerryB]

Both my '06 and the '11 would/will lock the brakes at 0 speed with the gain set to "10".

 

[Powerstroke2000]

Interestingly, I have an '09 F-450 with this same issue, where with the controller, the brakes seem to come on, but not with the brake pedal itself.
So, I'm not sure the year of the truck has alot to do with it?

I've been to a "hitch" shop, and was told all was fine, took it to the dealer at the original poster did, and was told the same thing...albeit, the dealer charged me for their time.

I've been working at this issue now for nearly two weeks without an answer (seems to be a complex issue) and I have a trip upcoming, so I'm assuming I'll just have to forgo the problem and use the controller manually! It would be nice to know at least, if it's the truck, or the trailer...as I've changed some trailer connections in my troubleshooting, as well as the trailer ground, which all seemed fine initially.

I did notice, even using my controller on level 8, that the trailer (pavement) wasn't locking up, but did seem to be braking (holding back) fine.
In my troubleshooting, I'm finding this to be a popular issue, but I haven't come across any telling me exactly what they found, as after asking the questions...and hopefully getting things fixed, no more posts obviously have been posted.

Thanks in advance on any advice/comments.

 

[FordService]

Interestingly, I have an '09 F-450 with this same issue, where with the controller, the brakes seem to come on, but not with the brake pedal itself.
So, I'm not sure the year of the truck has alot to do with it?

I've been to a "hitch" shop, and was told all was fine, took it to the dealer at the original poster did, and was told the same thing...albeit, the dealer charged me for their time...

Hi Powerstroke2000,

Let me lend a hand. PM me your name, phone number, VIN, mileage, and dealer info.

Ashley

 

[klassic]

I too have very poor braking from my integrated controller on my 2012 f350.
It is set at 10 all the time and even with manual lever it just barely applies the brakes.
My service manager tells me this is how the controller works, it WILL NOT lock the brakes.
I do not have enough braking power, no if ands or buts.
I can feel the trailer pushing the truck.. I had an emergency lock up on the interstate and my rig pushed my f350 (with my foot pushing the pedal through the floor board) right passed a semi... Lucky for me there was enough room on the shoulder.

Based on ford telling me there is nothing wrong with my controller, I have put over $1000 into shops working on my trailer brakes... To no avail.
I have since given up and traded in the trailer and bought a new 2016... Same thing, no braking power.
The trailer dealer did good will and worked on the brakes... They are fine.
It is the truck with the problem.. It has been since I took it off the lot in 2011.
It is my 3rd Super duty with an integrated brake controller. IT DOES NOT WORK CORRECTLY.
I am beyond frustrated with ford.

 

[FordService]

I too have very poor braking from my integrated controller on my 2012 f350...

Hi klassic,

I want to do what I can to help with your brake issues. How many miles are on your truck? When was the last time you were at the Ford Dealership for this? I'm on the case. :thumbsup:

Crystal

 

[klassic]

I went to the dealer in early 2012 to have them check the controller because I had traded in my 09 f250 (with a PERFECT working controller) and the first time I towed my 14000 lb trailer with the new 2012 I had VERY poor braking.
They said the controller was working properly.
Mileage was under 10000 miles then.
Conveniently enough, my dealer has no record of this complaint. (????)

Based on them telling me there was nothing wrong with the controller I had over $1000 worth of work and tests done on my trailers brakes... Until the trailer mechanic was frustrated and said he couldn't figure it out.

I drove with my controller set at 10 for the last 4 years ... Very cautiously.
With 2 very dangerous situations along the way.

Two months ago I had had enough, and bought a new 2016 trailer (partially based on the fact the old rig had bad brakes).
Same thing.. Poor brakes.
Trailer dealer conclusion... Truck controller.

Back to Ford dealer last Friday... Truck has 71000 miles.. They have no record of my first complaint. They now will charge me for diagnosis... And Ford has no way to properly test the controller and no real understanding of how it is supposed to work anyways.
My solution to this problem, which they won't agree to, PULL MY TRAILER WITH ANOTHER TRUCK AND SEE IF IT WORKS CORECTLY.
Simple! Case closed.
I would do this on my own, but I don't know anyone with a plus 2012 truck with a fifth wheel setup. I've been looking for 4 years.

Service manager says this is how the controller works and will talk to engineering and give me a call back. I'm still waiting
I'm not holding my breath.
And I am certainly not paying 100's to thousands for a new controller. When there has been a problem since day one, and I have wasted money and time on thinking it was the trailer. Not to mention the multiple brake jobs on my truck because the truck does all the stopping.

Fifth brand new ford truck.. 3rd brand new diesel superduty... Most likely the last.

 

[FordService]

...Back to Ford dealer last Friday... Truck has 71000 miles.. They have no record of my first complaint. They now will charge me for diagnosis... And Ford has no way to properly test the controller and no real understanding of how it is supposed to work anyways...

Thanks for responding, klassic. Let's get this pushed up the chain to your regional customer service manager; they'll work with your dealership to get this resolved. To make that happen, PM me your full name, best daytime phone number, VIN, current mileage, and servicing dealership. I'll take it from there. :thumbsup:

Crystal

 

[FordTruckDriver]

2014 F350 with the same IBC problem

Previously I had a 2010 F150 with a 30' travel trailer (7.5K lbs). No issues with the integrated brake controller. Generally operated with the gain set somewhere between 4 and 6 depending on how heavy the trailer and truck was loaded down.

Now I own a 2014 F350 DRW with a fifth wheel and the trailer is pushing me around. I have to use the manual brake control switch to get enough braking action from the trailer brakes even with the gain set at 10. Granted the trailer weighs 16K lbs. However, I also have two large cargo trailers that I also pull on occasion with the truck and regardless of the load (empty - approx. 3k lbs or full 10k lbs) I have to set the gain at 10 and use the manual actuation if I don't want to get pushed around. I have pulled the two cargo trailers (when they are empty) with a 2005 suburban with an aftermarket brake controller. I can easily feel the trailer brakes assisting during braking with the suburban. My conclusion is that the IBC in the Ford is not working properly based on previous experience with an IBC in a Ford truck and due to the fact that I have two trailers with known good brakes that I have pulled with another vehicle.

The dealer scratched their head and requested that I bring the truck and trailer in for them to look at it, but based on the threads, I am reluctant to start throwing money at a problem only to be told it all works fine.

What luck has anybody had in getting this problem resolved?

 

[KAN]

I went to the dealer in early 2012 to have them check the controller because I had traded in my 09 f250 (with a PERFECT working controller) and the first time I towed my 14000 lb trailer with the new 2012 I had VERY poor braking.
They said the controller was working properly.
Mileage was under 10000 miles then.
Conveniently enough, my dealer has no record of this complaint. (????)

Based on them telling me there was nothing wrong with the controller I had over $1000 worth of work and tests done on my trailers brakes... Until the trailer mechanic was frustrated and said he couldn't figure it out.

I drove with my controller set at 10 for the last 4 years ... Very cautiously.
With 2 very dangerous situations along the way.

Two months ago I had had enough, and bought a new 2016 trailer (partially based on the fact the old rig had bad brakes).
Same thing.. Poor brakes.
Trailer dealer conclusion... Truck controller.

Back to Ford dealer last Friday... Truck has 71000 miles.. They have no record of my first complaint. They now will charge me for diagnosis... And Ford has no way to properly test the controller and no real understanding of how it is supposed to work anyways.
My solution to this problem, which they won't agree to, PULL MY TRAILER WITH ANOTHER TRUCK AND SEE IF IT WORKS CORECTLY.
Simple! Case closed.
I would do this on my own, but I don't know anyone with a plus 2012 truck with a fifth wheel setup. I've been looking for 4 years.

Service manager says this is how the controller works and will talk to engineering and give me a call back. I'm still waiting
I'm not holding my breath.
And I am certainly not paying 100's to thousands for a new controller. When there has been a problem since day one, and I have wasted money and time on thinking it was the trailer. Not to mention the multiple brake jobs on my truck because the truck does all the stopping.

Fifth brand new ford truck.. 3rd brand new diesel superduty... Most likely the last.

I am having the same problem with my 2012 F250. The controller worked great until this spring. Each year first time out I use the controller manually to lock the trailer brakes on gravel.each year it would lock the brakes on a 5.5 setting. This year would not lock up on even a 10.0 setting. Like others I took my trailer in and had the brakes checked and adjusted. With the wheels off the ground using the controller (not the brake pedal) the brakes lock. I took the truck to Ford and had it checked they say everything is OK. I asked about the power output, they said 12 volts, I said what is the output in amps, more amps equals more power equals more stopping power. They said the ford repair manual does not give any amperage output for the various controller settings. How can they say it works if the don't what the power output should be. Does anyone out there know what the output in AMPS should be for the various controller settings.

Thanks Ken

 

[KAN]

2012 F250 Trailer brake controller

Does anyone know the output in AMPS at the trailer plug for the various controller settings. The Ford dealer cannot find anything in the the repair manual. More AMPS equals more braking power. Set on 10.0 I am getting about 10 AMPS. Since the controller is protected by a 30 AMP fuse I would expect something much higher.

Ken

 

[vdriveride]

Same problem 2015 F350

Previously I had a 2010 F150 with a 30' travel trailer (7.5K lbs). No issues with the integrated brake controller. Generally operated with the gain set somewhere between 4 and 6 depending on how heavy the trailer and truck was loaded down.

Now I own a 2014 F350 DRW with a fifth wheel and the trailer is pushing me around. I have to use the manual brake control switch to get enough braking action from the trailer brakes even with the gain set at 10. Granted the trailer weighs 16K lbs. However, I also have two large cargo trailers that I also pull on occasion with the truck and regardless of the load (empty - approx. 3k lbs or full 10k lbs) I have to set the gain at 10 and use the manual actuation if I don't want to get pushed around. I have pulled the two cargo trailers (when they are empty) with a 2005 suburban with an aftermarket brake controller. I can easily feel the trailer brakes assisting during braking with the suburban. My conclusion is that the IBC in the Ford is not working properly based on previous experience with an IBC in a Ford truck and due to the fact that I have two trailers with known good brakes that I have pulled with another vehicle.

The dealer scratched their head and requested that I bring the truck and trailer in for them to look at it, but based on the threads, I am reluctant to start throwing money at a problem only to be told it all works fine.

What luck has anybody had in getting this problem resolved?

I have the exact same problem, dealer was no help. Have you had any luck in solving this?