Troubleshooting Electric Trailer Brake Controller Not Fully Engaging Trailer Brakes

Question

Question:

I just installed the Prodigy 2 brake controller and followed the instructions for adjustment but could not get the brakes on my 25 foot travel trailer to lock up even on the highest boost setting, what do I do next? The controller is working but I could not get the brakes on my trailer to lock up like they say in the instructions for adjustment.

asked by: Tim M

0

Expert Reply:

One issue could be that the brakes need to be adjusted. If you have manual adjust brakes then you will need to rotate the little wheel on the inboard side at the bottom of the brake assemblies. This wheel adjusts how close or far the shoes are from the drum.

It could also be a problem with the trailer brake magnets. Make sure that the trailer is not connected when performing tests on the trailer brake magnets. Start by visually inspecting the magnets for wear. If you can see the windings coming through on the magnets they will need to be replaced.

If the magnets look good, check the wiring connections for loose or broken wires and make sure there is a good connection. Also check for corrosion and be sure the ground wire is attached to a clean bare metal surface.

If the wiring is also in good shape you can test the magnets with a multimeter like # PT89ZR if needed. I have included a link to an FAQ article that explains the process and what to look for.

You will also want to make sure the brake controller is mounted properly according to the installation instructions. I have included a link to the installation instructions as reference. If you have to remount the controller, go through the setup process again as if it were the first time.

If everything checks out with the trailer brakes and the controller is mounted correctly, use the multimeter to test the blue wire on the brake controller. It should show full power (if the brake controller is set to full power) when you engage the manual override or step on the brakes. If it does not show the correct amount or none at all then there is a problem with the internal circuitry of the brake controller and it will need to be replaced.

expert reply by: Michael H

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Answer 1

You don't have to do an initial adjustment with self-adjusting trailer brake assemblies, and since it's challenging for the reasons you mentioned I don't recommend doing it and personally wouldn't if it was my trailer. Easiest…

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Answer 2

The issue seems to be different adjustment than the other side. Most likely the time delayed onset of the braking pressure is locking up the one side of the trailer before the other due to it being a tighter adjustment. What you can do is tow the…

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Answer 3

Since the trailer was off of the ground it would not take much voltage to stop the wheels from spinning so they may be getting power but they may not be getting enough power due to a short or wiring issue. But 9 times out of 10 weak trailer brakes…

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Answer 4

For the 2 wires coming off the brake magnet, either wire can be used for either ground or power. You will just want to make sure that the ground wire has a good connection to a clean, corrosion and paint-free location on the trailer frame. A bad…

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Answer 5

If the brake magnet is worn to the point that the windings are visible then you know it's time to replace the magnet. However, magnets can also fail without the visible signs of wear. Check out the FAQ article I attached on testing brake magnets…

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Answer 6

The blue wire coming from the brake controller to the trailer brakes is the brake power output wire used to tell the trailer to apply the brakes once given the response from the brake controller. Therefore, you should not have a constant charge to…

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Answer 7

In order to determine the torque rating for the lug nuts on your trailer you will need to know check out the chart I attached that shows all of the torque specs for all the trailer lugs available based on stud size, wheel material and wheel size.

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Answer 8

The difference between the Class II and Class III hitches has to do with their Gross Trailer Weight (GTW), their Tongue Weight (TW), and their Hitch Receiver Size. Class II trailer hitch receivers have a 1-1/4 inch receiver and can be rated up to…

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Answer 9

A 4-Way trailer connector has the basic lighting functions only; running lights, left turn signal and brake lights, right turn signal and brake lights, and ground. A 7-Way has these functions and a 12 volt circuit, a circuit for electric trailer…

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Answer 10

To determine the size of the brake assemblies you need you have to measure the depth and width of the hub drum on the axle like what you see in the picture I attached. The most common size is 2-1/4 inch wide like the #T4071600-500 that you…

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Answer 11

I did some checking and the hub/drum we offer that will work for you is the part #8-430-5UC3. This uses the same bearings as the 8-415 and will be an exact fit aside from the fact this is a non-ABS setup and the 8-415 came in an ABS setup and non-ABS…

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Answer 12

To find the load capacity for your axle you should look on the trailer VIN plate or sticker that lists the VIN number. The weight rating of the axle should be listed on that same plate or sticker. Also, the axle could have a tag or plate on it that…

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