Weak Trailer Brakes Using Valley Journey HD Brake Controller on a 2005 Toyota Tundra  

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Helpful Expert Reply:

On the 2005 Toyota Tundra, if it came with a factory installed 7-Way trailer connector then the brake controller should have plugged into a factory port on the truck. If it did check to see if it has a separate ground wire like harness # 3040-P. A common issue on this truck is that the factory ground in the port is not sufficient for a brake controller. Adding a separate ground could be all you need to do.

To check the brake controller you will want to use a multimeter such as # PT89ZR. Sever the blue wire a few inches back from the controller and test for voltage on the end coming from the controller with the controller set to max. You should be getting 12 volts or so with the manual override. If not or if it shows power all the time there is something wrong with the controller and it will need to be replaced.

It is shows the correct power then reattach the blue wire. Make sure the controller is not mounted outside of its range nose up or down and that it is not tilted or turned to the side.

Next you can go back to the trailer connector and test for voltage there while someone applies the manual override in the truck. If the voltage is not about 12 volts there then there is likely a loose connection or break between the controller and the connector at the back you will need to track down.

Also check the vehicle and trailer side connector for dirt and corrosion. They should clean and corrosion free inside and out.

There could also be an issue with the trailer brakes. Make sure the magnet ground wires are attached to clean and corrosion free bare metal surfaces. The power wires should not be frayed or pinched anywhere.

Visually inspect the magnets and if you can see the copper windings coming through they will need to be replaced. To further test the brake magnets and brake controller you can follow the steps in the help articles I have linked.

Also make sure the brakes are properly adjusted. There should be a slight but constant drag of the pads on the drum.

expert reply by: Michael H

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