Troubleshooting Trailer Brakes That Show Intermittent Overload Error Message on Prodigy Controller

Question:

I push on the breaks and they apply then go to OL and then apply, We have checked all grounds break away, hooked my truck to two different trailers they worked fine. we do not read any shorts and the magnets on the trailer ohm good. the higher the mode on the controller the more frequent it happens.

asked by: Eric O

Expert Reply:

It sounds like your Prodigy brake controller in your 2004 Dodge Ram Pickup is sensing an intermitting short in the trailer wiring. Since you have checked the brake magnets and have found them to be okay, I suggest tracing the entire brake circuit for signs of damage or corrosion.

Follow the brake circuit wiring from each brake all the way to the trailer plug. Look for cracked insulation and spots where it is worn off, especially near points where the wire bends and where it comes into contact with the trailer frame. Also check the trailer plug for any signs of internal corrosion. This can be tough to spot if it started inside the plug housing. A replacement 7-way plug like # H20046, some butt connectors like # 44-5310A and junction box # 38656 make replacement easy.

If you can test your trailer with a different truck and you find it works properly then there could be an internal fault in the controller.

expert reply by: Adam R