Troubleshooting Intermittent Brake Controller Operation and Error Code
Question:
When the trailer is hooked up as usual and I press on the break the contoller gives me an E 50 of the time and the normal number the other 50 of the time. It seems to only be breaking when the normal number is showing.
asked by: Jean
Expert Reply:
It sounds to me like you have a loose connection somewhere in the brake controller wiring that is causing the intermittent functionality of your brake controller. The E you are seeing on the controller is an error code. First thing I would check is to see if your manual brake override brake lever will work operate the brakes when your brake controller is reading the E error code. If the override does work when you are seeing the E, you most likely are having a problem with red stoplight switch wire that is coming off of the brake controller. You would want to check the condition of the connections of that wire at the controller and where it runs to a stop light switch.
Next, I would try severing the blue wire at the back of the brake controller, leaving plenty of wire to reconnect it, and then test all of the wires going into the brake controller and coming out of it. This will tell you if the controller is functioning correctly or not. Also, be sure the ground on your controller is good, if you are not sure try running it to the battery of your vehicle.
Next, I would check the connector that plugs into your trailer for loose wires or corrosion in the connector that may be causing your connection problem. If you see an obvious problem, go ahead and fix it. If you do not see anything that would cause a problem, you will want to get a hold of a circuit tester like, part # PTW2993, and have a friend apply the brakes while you first, test the circuits on your trucks brake trailer plug.
If you have a 6 way connector on your vehicle you will be checking the upper left post for voltage while your friend presses the brake. If you have a 7 way connector on your vehicle you will be checking the bottom right pole as your looking into it for voltage. If you have voltage there you know its not on the truck side of the wiring. If you do not have voltage there you will need to check the wiring, on the back of the plug, for any obvious damage and repair it. If everything checks out you will need to trace the wire all the way back to the brake controller looking for any problems on the way.
If you still have not found your problem you will want to check the trailer connector with a circuit tester while it is connected to your truck. You will want to check the pole that has the blue wire coming out of it for voltage while your friend presses the brake. Regardless if you have power there or not, try wiggling the connector to see if you can get a different result while you are checking the connection, this will help determine if you have a connector that is not making good, solid contact.
If you still have not found the problem you will need to trace the wiring back to the brake assemblies looking for any obvious problems such as loose wire or corrosion.
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