Weak Output from Trailer 7-Way Connector with Brake Controller on 2007 Dodge 2500 6.7L Diesel  

Question:

Expert Reply:

You have already performed a great deal of the troubleshooting steps by trying your truck with multiple brake controllers, connecting it to multiple campers and substituting a different truck. (Thank you!) Based on the testing steps you have already taken, the problem would seem to have been isolated to your Dodge.

I doubt that the Dodge brake pedal switch is the problem. The brake switch does tell the controller to generate a braking signal for the camper, but it does not tell it how much of a signal; that is controlled by the inertial sensor within the proportional brake controller. If you had no signal at all that could be the brake switch, but since the problem is a weak signal at the 7-way (even with the manual brake control engaged, and with two different brake controllers), it sounds like the problem lay within the Dodge wiring.

Your problem could result from even a slightly dirty, corroded or loose connector (or individual connector pin) anywhere from the dash all the way to the 7-way. Corrosion can sometimes appear as a green or white film (connectors do not have to look badly corroded to have issues). Even a small amount of oxidation on a connector could inhibit the signal transmission.

Carefully inspect all wiring, from the connector to your brake controller under the dash, all the way through to your 7-way at the rear.

You may want to start at the 7-way connector since this part is exposed to the elements. Use a multimeter (such as part # PT89ZR) to test the voltage output on the brake controller output pin, at the 5:00 position. Read the voltage from the pin. Now disconnect the connector harness from the vehicle wiring and re-test at the corresponding pin on the vehicle harness (the one with a blue brake signal wire). If you read a higher voltage on the harness than on the connector then you have a bad 7-way connector and can replace it with part # 42145. If the connector and harness show the same voltage then you need to continue checking the rest of the wiring.

A loose (white) ground wire anywhere in the wiring could also cause this problem; if the controller was hard-wired make sure the white ground wire is firmly attached to the battery negative terminal. Check for any wire with cracked insulation. Wires can develop wear spots in the insulation from the normal vibration that occurs during driving, especially if the insulation comes into contact with other parts of the vehicle.

Also check for any pinch points around the wires and re-route them away from suspension and exhaust components if any are nearby. Any badly damaged wire should be replaced and any worn spots should be securely sealed with electrical tape.

I have attached an FAQ article on malfunctions with brake controllers; this may be helpful for further troubleshooting.

We do recommend use of a dielectric grease to protect all connections, such as part # 11755.

expert reply by: Adam R

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