Troubleshooting an Erratic Tekonsha Voyager Brake Contoller on a 2014 Ram 3500 Truck

Question:

I have used the voyager on several different vehicles in the past and have had no problem with them. I have a 2014 Ram with the integrated brake controller that quit working. I by passed it and installed the voyager. The braking is weak and erratic. I installed a 30 amp circuit breaker. If I use the brakes very much, like in heavy traffic, the circuit breaker will trip. I have a lot of experience with wiring but this has me stumped.

asked by: Danny L

Expert Reply:

It sounds like you are getting a high amperage draw somewhere in the electric brake system. Most times this is caused by a faulty brake magnet. The magnets will get worn and will cause lower or higher amp draw that could cause erratic use or lead to causing the circuit breaker to trip.

You can test the amp draw on the brake magnets by using an multimeter, like # PT89ZR. To test with a multimeter, first you will connect the ammeter inline with the blue wire exiting the back of the brake controller or use the brake controller's diagnostic readings.

Check the amperage. I've attached a help article that lists the correct amperage range. If the amperage is greater than the specified amount in the attached article, then you will need to replace the magnet or magnets. If the reading is less than the specified amount, the wire leads coming out of the magnets are bad and the magnet or magnets should be replaced.

If the magnets test out to be within specs, then a ground short in the wiring may be the issue. You need to then check the wiring to make sure all your grounds are secure or there are no bare wires that could be rubbing on metal causing a short.

You also can check your Tekonsha Voyager Controller, # 39510, to see if the issue is there. To check the output voltage at the rear of the controller, cut the Blue wire 5-6 inches behind the controller. Install the multimeter between a chassis ground and the Blue wire. When activating the brake controller, read the output voltage coming from the brake controller. If the reading is + or - 1 volt between 12-13 volts then that controller is good. If there is a fluctuation or a large drop or spike in the voltage, then there may be an issue with the controller and it will need to be replaced.