Prodigy Brake Controller 90885 Has Low Braking Power Compared to OEM Brake Controller

Question:

We have two Chevy 3500 HD trucks running the Prodigy and 3 Chevy 2500 HD trucks with the factory OEM brake controller built into the vehicle. Pulling the same trailer with 60 gain it will lockup the wheels, but the same trailers are not braking nearly as hard and to be honest not enough from the Trucks running the Prodigy. Please provide any recommendations and we appreciate your help.

asked by: Performance

Expert Reply:

Proper operation of the Tekonsha Prodigy Brake Controller, part # 90885, requires that several installation conditions be met. Please refer to the linked installation video and written instructions.

The Prodigy is intended for use with electric brakes only, not electric-over-hydraulic trailer brakes.

The gain setting should be adjusted to match the tow vehicle and trailer combination. This may vary from vehicle to vehicle. You can try adjusting the boost control to a higher setting to increase braking power if you have not already done so.

It is essential that the controller be mounted within a specific range of vertical alignment, from zero degrees (level flat) to no more than 70 degrees vertical pitch (nose up). It will not operate properly if there is any deviation from alignment to the direction of forward travel. If the mounting position is out of alignment the inertial sensor will not properly detect the tow vehicle deceleration, and so will not generate the proper output signal to the trailer brakes. (The OEM controllers in your other vehicles have fixed positions that are not subject to misalignment).

Any nearby electronic devices that generate RFI (radio frequency interference), such as cell phones and two-way radios, can impair the performance of the controller. No such items should be within 12 inches of the Prodigy.

If the two vehicles using the Prodigy are older than those with the OEM brake controllers there may be an issue with the condition of the trailer connectors. You might check them for signs of any corrosion and clean with a spray-on contact cleaner and wire brush (available from an auto parts dealer). Even mild corrosion (which can appear as a thin whitish or greenish film on the contacts) can impair signal transmission to the trailer brakes.

If the Prodigy controllers were hardwired, check that the white ground wire is secured to the battery negative terminal.

I have included an article on brake controller troubleshooting that might be helpful to you as well.