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Blown Fuse & Relay with New Utility Trailer Running Lights  

Question:

tow vehicle - 2004 Ford F-150 with factory installed trailering pkg trailer1 - small boat trailer - brake/turn lights and 1 forward side marker light on each side. trailer2 - brand new single axle utility trailer - brake/turn lights and 2 forward side marker lights on each side. boat trailer works great - has for years. problem with new utility trailer - all is fine upon hooking up trailer and wiring connector, usually early morning dark - all lights working. Several 5 to 20 miles down the road, the fuse and relay blow out for the running lights. Brake/turn signal lights still operate fine, as they are on separate fuses. I went from a 20 amp fuse to 25 amp, with the same result. Now back at 20, and trying to figure this out.. as the relays are NOT exactly inexpensive $17 each! Visual inspection of the wiring and bulbs on the trailer appears to be intact. A sight wiggle on the license plate light broke off the internal wire to the built-in rear side marker light bulb. I am on the way to the store for a replacement unit. any suggestions for diagnosis would be appreciated. Thanks!

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Expert Reply:

One possibility is that the running lights on the new trailer are simply drawing too much current and are blowing the fuses. Trailers can be equipped with either high-efficiency LED lights or standard incandescent bulbs, which draw about 10 times the power. If the new trailer has many more running lights than the boat trailer, and/or if they are incandescent types, then they may be overloading the vehicle wiring.

It is also possible that the running light wiring is pinched, has a bare spot somewhere on its insulation or has a bad connection at the trailer connector pin or at the light socket end. Any of these conditions could cause this symptom by creating an intermittent short. It may be that when you are at speed on the road, there is enough vibration/movement of the wiring to create the fault condition that causes your fuse and relay to fail.

I suggest you thoroughly check the ground connections on the trailer from end to end to verify that none of the possible fault conditions listed above apply. Check the trailer tongue where the ground wire attaches. Its also a good idea to check the bulbs and sockets for signs of corrosion and to confirm a secure ground connection either by their attachment hardware or ground wire. An application of dielectric grease will help to keep good connections secure.

Please note that part #118376 is not the correct harness for your Ford F-150. The correct harness is part # 40185.

Last, I have attached an FAQ article on trailer wiring that should prove helpful to you. Since your problem is specific to the one trailer, and since it is limited to just the running lights, I would focus my attention on the wiring for the running lights on the new trailer. Often this will be a brown wire.

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Adam R

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