Trailer Brakes Working Intermittently

Question:

2003 Ford F150 300 6cly. Towing 2013 Dutchman 21. Have the TK90160 controller hooked up via the cable made for the vehicle. Has been working fine for the last 2 years. 3 months ago driving back from a campground noticed the 2 dots on the controller indicating no brakes. Tail lights, brake and turn lights still working fine. I hooked truck up to 2 other trailers, controller worked fine. Hooked back up to mine- shows NC. I bought new brakes from etrailer, took off the passenger side wheel, brake looks like it is still in good condition with plenty of wear left. I checked the wiring for any obvious breaks, pulled the connection box open, checked the wiring in it, do not see any problems. Put all back together, had to go on a camping trip close to home so hooked back up - good brakes no problems. Worked fine next 2 trips, this weekend coming back from a 2 1/2 drive from trip, noticed half way no brakes again - lights still working on trailer. Hooked up to another trailer again, controller works fine. Obviously problem is in trailer, but not real familiar with trailer wiring and dont know quite where to start. Is it possible a brake itself is bad and I should go ahead and change, or you think its a wiring issue? I was planning on first starting to replace wiring one piece at a time. Suggestions?

asked by: Paul K

Expert Reply:

Thanks for all that info, and if I had to guess it is indeed the brake wiring but could be the brakes, or more specifically the magnets. You'll want to visually inspect the magnets, and if you can see the copper windings coming through the magnets, that'll be an indicator to go ahead and use the # AKEBRK-35-SA brakes.

Otherwise, first inspect the power wires going to the magnets and look for wiring that is pinched or otherwise damaged. If you can't see anything obvious, check the ground wiring. Make sure the ground wires are attached to bare metal surfaces and free of any paint, dirt or corrosion, and if you need new brake wire use Deka Jacketed 2 Wire, 10 Gauge, Brake Wire - per Foot # 10-2-1.

expert reply by: Kyle S