Troubleshooting Tekonsha Voyager Brake Controller Installed on 2003 Dodge Ram 2500  

Question:

Expert Reply:

There are a few possible issues that might be causing the problem you are experiencing.

The most common of which would be a damaged, dirty or corroded trailer connector on the vehicle or trailer. Closely examine the connectors for dirt or corrosion. If you can see green or white corrosion in the sockets or on the pins, there is a good possibility that the corrosion has spread to the interior of the connector and might be intermittently obstructing the controller from reading the trailer. Also make sure that the actual wire connections at each terminal on the vehicle and trailer connector are tight. If damage or excessive corrosion is found, replace the connector as needed.

Another possibility would be a short in the brake output circuit either on the vehicle or on the trailer. If possible, try the controller using a different trailer. If the problem persists, the problem is on the vehicle side. If it goes away, examine the brake output wire on the original trailer. Look for a pinched wire, or cracked, worn or missing wire insulation. Make sure that both connections at each brake magnet are secure, with one wire grounded to the trailer frame and the other connected to the brake output circuit.

Another possibility is a worn brake magnet. If the brake magnet is excessively worn, a short can also be caused. Pull a hub off, and examine the face of the magnet that rides against the armature (inside) surface of the brake drum. If the face of the magnet is worn to the point where you can see the interior copper wiring, the magnet should be replaced.

If the above mentioned suggestions do not locate the problem, please get back with me and we will check some other less likely possibilities.

I have linked you to our Brake Controller Troubleshooting FAQ article that you might find helpful.

expert reply by: Mike L

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