Primus IQ Brake Controller Not Working on a 2006 Ford Super Duty Truck  

Question:

Expert Reply:

The NC error code on the Primus brake controller # TK90160 means that the controller is not sensing the trailer. The first things to check are the vehicle and trailer side connectors. Make sure they are clean and corrosion free inside where the wires attach and outside on the pins.

There are additional tests you can perform to determine if the problem is with the brake controller or something else. 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. 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.

If the truck side checks out fine then it could be the wiring to the brake magnets or the magnets themselves. Inspect the power wires to the magnets and look for pinched, frayed, or damaged wires and fix as needed. Make sure the ground wires are attached to clean and corrosion free bare metal surfaces.

You can visually inspect the magnets and if you can see the copper windings coming through the magnets will need to be replaced. To further test the magnets you can follow the help article I have linked. I have also included some help articles on testing and troubleshooting brake controllers for you.

expert reply by: Michael H

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