How to Troubleshoot a Brake Controller that only Engages with the Manual Lever  

Question:

Expert Reply:

There are a few possible issues that could be causing the brake controller not to engage on your 2002 Chevy Silverado.

First, I would check to make sure that your stop light wire from the brake controller, usually the red wire, is connected to the correct wire coming off your brake pedal. Go to the point at which your stop light wire is connected, and test the wire with a circuit tester, # PTW2993 if needed.

You should receive a signal when the brake pedal is pressed and should not have a signal when it is released. If you are not getting a reading with the brake pedal is pressed, the stop light wire will need to be reconnected to the wire that does receive a reading as described.

The 1999 through 2006 Silverado models without a factory-installed 7-way connector do require some connections under the hood as well.

Did you install the 7-way yourself, or did it come from the factory? If the 7-way did not come from the factory, in order to get power to the electric brake and 12v wires on your 2003 Chevy 1500, you will need to connect them under your hood as well.

First, you will remove the bracket in the corner that is closest to the driver to access the accessory fuse block. Once you reveal the fuse block, you will remove the top and lower covers to access the two wires, which will be next to the block and on the cab side.

The red wire, which is the 12v wire for the brake controller, will have a ring terminal on it. Use the ring terminal to connect this wire to the closest positive post. You will also need to install a 30amp fuse in the block, in the port closest to the positive post.

The blue wire will have a plug, which will be clipped off. The blue wire under your hood would then be connected to the blue electric brake wire from the brake controller, but this should already be done if the manual lever actually activates your brakes.

I recommend taking a look at our FAQ on installing a brake controller on a 1999-2006 Chevy truck.

Another issue would be if you are using a brake control wiring adapter that is incorrect for your particular vehicle and wires are located on different pins than they should be. I would double check that the adapter you installed is the correct application for the 2003 Chevrolet Silverado.

If none of these options solve your problem, it might just be that the unit itself needs to be replaced.

expert reply by: Sarah L

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