Tekonsha Voyager Brake Controller Not Activating Trailer Brakes When Brake Pedal Is Pressed

Question:

I had a Tekonsha Voyager brake controller installed on my 2003 Ford F-250 when it was brand new. The controller worked fine for 9 years. Now, the controller will only activate when I use the Manual Slide Knob. My truck came with a tow package. I traced the red wire to the connector that connects into the trucks wiring harness and cannot find any loose wires. Do you have any recommendations? Is there a way to test the controller to see if it has gone bad? Any advice will be greatly appreciated. Thank you!!

asked by: Kevin

Expert Reply:

Yes, we can help you test your brake controller and determine if the controller is bad or if there is a wiring issue that is causing the problem on your 2003 Ford F-250 pickup. Lets start with the easiest things first. Be sure that when you are testing the trailer brakes with the brake pedal that the vehicle is moving. The trailer brakes will not apply with the brake pedal if the vehicle is not moving because of the proportional sensor.

The first thing I would check is the red wire that provides power to the brake controller when the brake pedal is pressed. Use a circuit tester, like part # PTW2993, and make sure that there is power on the red wire when the brake pedal is pressed. If not, check the vehicle brake lights and third brake light, the fuse for the brake lights and/or third brake light may be blown, and you just have not realized it yet. If this is the case replacing the fuse should solve the problem.

Next, make sure that the brake controller power knob is not set to 0 and that the brake controller is installed between -20 and +70 degrees of level and that the level adjustment is properly set.

If those steps do not solve the issue, the next step is to test the power into the brake controller. You should have 12 volt power going into the brake controller on the black wire. You should also check to be sure that the brake controller is properly grounded. If you are unsure of the ground you can attach a ground wire to the white wire at the back of the controller and temporarily run it to the battery negative post for the best ground connection possible.

The blue wire is the output wire. If none of the above steps solves the issue, sever the blue wire 6 inches from the back of the brake controller, and perform a test on the brake controller to see if you get power when stopping with the brake pedal. If so there is a problem on the trailer side or at the vehicle and trailer connectors. If not, the brake controller is bad and will need to be replaced.

expert reply by: Robert G

Toby

3/18/2013

solder two wires 3 feet long to an old head light globe and then push onw wire in the earth on plug and the other to the electric brake output,place the light where you can see it from driver seat and test your your brake unit. the light will light up if the unit is ok if no light adjust every thing if still no light you have a problem simple