Tekonsha Voyager Trailer Brake Controller Does Not Work when Installed on a 2007 Toyota FJ Cruiser

Question

Question:

I had a 2007 FJ Cruiser with a Tekonsha brake system installed. This vehicle did not come with the factory tow option and a Curt 55567 adapter and wiring kit from etrailer was used to connect to the vehicle wiring. Never had a problem with it. that vehicle ended up in a canal long story and was replaced with another 2007 FJ Cruiser. This one came with the factory towing package. I installed the controller and rather than install the Curt adapter I simply tapped the factory flat connector for lights and ground. Direct lines were installed for the controller brake and 12v lines to the 7-pin connector. When I first tested the system it seemed to work fine but when I re-connected it to tow, the 40-amp breaker kept cycling with no brake applied. Since the existing controller had been in the older vehicle I purchased a new Tekonsha Voyager and installed the controller with no change in the problem. I took the vehicle to an RV repair where they were able to give me manual-only control. I need to look at the connector to see what they did with the wiring, BUT, before I get to far into this, I have several questions. 1. The toyota factory tow kit includes two relays, the function of which I cannot determine from the factory documentation. By tapping into the factory flat connector I have put those relays in the circuit. Q: Is there any known problem re: installing the Voyager, or any brake system, using the factory wiring and circuitry? Q: Would I be better off to use the Curt adapter and bypass the factory towing circuit? I have considered that there might be a problem with one of the trailer brakes but there was no indication of that prior to this new installation. ANY insight, guidance, instruction or prayers you can provide would be greatly appreciated!

asked by: Mkie H

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Expert Reply:

It sounds as if there was something that just was not connected correctly. There are a few things you can do to isolate the issue. First, start by fully applying the manual override and then let it snap back into place. Do this several times to clean the contacts inside the controller.

Next you will need to sever the blue wire a few inches from the back of the controller. Then use a circuit tester like # PTW2993 if needed to check the end of the blue wire coming from the controller. It should only show power when you apply the manual override. If it shows power at any other time, then there is something wrong inside the controller and it will need to be replaced. If it checks out, then reconnect the blue wire before continuing on.

Another thing to check is the trailer connector on the vehicle. Using the test light test your trailer connector pins while someone applies the manual override on the controller. If the signal is not reaching the trailer connector, then you know you have a broken wire or loose connection between the controller and the connector. The factory wiring should be fine for use with a brake controller but if you cannot find the issue then hardwiring it by bypassing the factory wiring would be the way to go.

While you are at the connector, look for and clean off any dirt and corrosion on the trailer connector pins. Also check the back of the connector where the wires attach. Then move on to the trailer and do the same thing with its connector. Make sure that the main trailer connector ground and the brake magnet grounds are attached to clean and corrosion free bare metal surfaces.

Next inspect the brake magnet wiring for any breaks. You can visually inspect the magnets as well. If you can see the winding coming through, then the magnets will need to be replaced. You can further test the magnets by following the FAQ I have linked on testing brake magnets.

expert reply by: Michael H

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