04.5-06 trailer brake problems

[Cumminsman]

i have an 06 and a friend of mine has an 04. 5 dodge. we are having problems with our brake boxes. i have a pilot sure pull (it is digital) that i took out of my 01 and put it in my 06. it worked flawlessly in the 01. but in the 06 it won't stay where you set the volts. it may show 6 volts one time and 8 the next or 12 or 3. and the 04. 5 has a teknosha voyager and the brakes are either locking up or feel like they arent working. any ideas? thanks, nick

 

[Dale]

I have the "06" 3500 with a Tekonsha Prodigy ( digital ). Went on my first towing trip with just the bike trailer. 180 mi. round trip. On the way up flawless, on the way back it kept fluctuating between . C. to . NC. to . . and I also noticed that I had no trailer brakes. The only thing I could find was that the rear plug kept working itself loose. You may check that, I am sure you have, and I am tightning the pin connectors and adding a little more grease. Hope thats the only problem as this is the first digital I've used. Good luck

 

[BHolm]

I used the Prodigy on my '05 for almost a year (and 30k miles) with no problems. I simply swapped it over the the '06 but I am still shy of the 500 mile rear axle break in reccomendation so I haven't verified that it works yet.



Electric brakes are a PIA period. My expereince is that it is almost never the controller causing the problems, almost always another wiring problem. Good Luck

 

[CPG]

Contact resistence is the main cause of most malfunctions of trailer brake problems. Disuse and sitting for a long time in storage. Be sure the Berg plug connectrion is tight and you use electrical contact cleaner often.

 

[TBrunet]

Went from an 00 to a 05 but had to rewire my harness as plug stayed the same but wire positions had changed in it according to dealer tech. Have had no problems since the change over.

 

[firemanram]

I installed the Prodigy , works great and I haven't had any problems . Sounds like a bad connection .

 

[KBalzuweit]

06 with a Prodigy and there harness, works great.

 

[Cumminsman]

i think that i have it fixed. it was the factory ground wire. ran a ground to the battery. no more problems. oops. didn't know you were supposed to wait 500 miles before you hauled a trailer with it. had the gooseneck hitch in 2 days after purchase and the first 480 miles were with a trailer behind it. break it in right. thanks, nick

 

[jwduke]

I use a Jordon Ultima 2020, no problems here either. Sounds like a dirty connection some where.

 

[jelag]

I have an 04 and a 05 and my boy has an 04. 5 we all pull using a different brands of brake controler in each truck. . we've had no problem but there was a thread here about someone having a problem and pulling the plug from the rear bumper and inspecting the connections to find them all full of corrision..... you might check your plug. .

 

[Cumminsman]

the only thing with that is. its brand new. it has less than 2000 miles and is less than 1. 5 months old. thats what has me scratching my head. thanks, nick

 

[RLighthall]

i think that i have it fixed. it was the factory ground wire. ran a ground to the battery. no more problems.

According to Prodigy, the 2nd gens' have an issue with the ground wire not being heavy enough; I don't know if the 3rd gens' have the same issue but I ran a separate ground under the hood as well. Also, I have to use a long velcro strap to keep my trailer connector from falling out of the socket. The spring loaded cover is supposed sort of lock the connector in place but it doesn't do it very well. I use the velcro strap to keep the connector and cover snuggled up to each other and haven't had a problen since...

 

[TexBamBam]

When I hooked up my trailer it locked up the electric brakes... and would not let the trailer move... . had to have the 03 rewired too... for the same problem. Is there a TSB on this?