Troubleshooting a Tekonsha Voyager Brake Controller that Only Works With a Test Light on the 7-way

Question:

Grounds and hot Leads seem to all be ok, unit wont light up green when connected checked all fuses and relays ,it has the toe package , ford 02 f150 , When i put the test light in the blue wire test light comes on when i hit the brake pedal and the unit seems to work ok with the test light still in the blue wire, pull it out it doesnt work , what do you think? I have used this unit for 3 years always worked fine ! PS Im a ford tech, 35 years !

asked by: Steve C

Expert Reply:

The reason the Tekonsha Voyager Brake Controller # 39510 seems to work when you use your test light to test the brake output circuit is because this controller is designed to only work when it senses a load on the brake output circuit (the brake magnets in your brake assemblies). It is designed like this so that the controller only sends voltage when a trailer is connected.

If the controller does not work with your trailer connected is sounds like the problem is somewhere on the trailer side of the setup. For some reason your brake controller is not sensing the brake magnets so it is not activating. This could be from corrosion in the trailer connector, cut or exposed wiring or even bad brake magnets.

I would first check out the connector and brake output wiring for any problems and fix as necessary. Next I would test the brake magnets.

I attached an FAQ article on testing brake magnets and troubleshooting brake controllers for you to check out also.

expert reply by: Jameson C