Tekonsha Voyager Brake Controller has Constant Power on Blue Wire After Improper Installation

Question:

I have a Voyager brake controller whose internal switch apparently is stuck closed. Long story short: Controller was installed last November by U-Haul. The red brake switch wire was attached to wrong hot side of brake switch. With other issues I had with my trailer brakes and winter setting in, I did not discover the error for a couple months. I have corrected that error, but now it appears the controller switch is stuck closed, as the blue wire is permanently hot. Do you know what is going on, and is there a fix for this?

asked by: Chris

Expert Reply:

It is possible that there is an internal short in the brake controller. But it may also heal itself if it resets. To reset it remove power from the controller for about 15 minutes (black wire). If the problem persists then you can continue to test the brake controller. What is the year, make, and model of the vehicle? there may be some caveat with the vehicle as well that explains the issue.

To test the controller, you can follow this procedure: In the truck cab you will need to sever the blue wire several inches from the back of the controller. Then use a circuit tester such as # PTW2993 to test the end of the blue wire coming out of the controller. It should only have power when you apply the manual override. If it shows power at idle, then there is something wrong with the controller and it will need to be replaced.

If it tests fine then reconnect the blue wire. Then move on to the truck side trailer connector. Many times, dirt or corrosion can cause a short in a trailer connector. Make sure the truck and the trailer side connectors are clean and free of corrosion inside and out.

You can test the brake output pin and it should only show power with the manual override. If it shows power any other time then there is a short somewhere between the connector and the brake controller you will need to track down.

expert reply by: Michael H