Brake controller problem, bad connection/corrosion?

[Billy Golightly]

Hey Guys, I've been running a Tekonsha Voyager series brake controller on my 03 just about since it was new without any problems until just a few months ago, when it quit on me. It turns green whenever I plug the trailer up to it, but when I press the brake pedal the light never changes colors like it use to. I went through all the adjustment/calibration settings as suggested in the paper work without any luck. The manual slider on the front does in fact change the color of the light. I decided I had probably just knocked something loose in it, as I have been in some very rough areas lately and have heard multiple times the pendulum setup in the Voyagers is a little precarious.



I got the new controller today (Voyager too, just a lot newer), hooked it up and it does the exact same damn thing as the old one. Everything is wired up as per Tekonsha's specs, I went through the calibration on the new one and nothing. The slider still does make it change though. After doing a little bit more digging I discovered that this may be attributed to a short in the system or poor connection. It happens on all 4 of my trailers I hook up to, so I'm going to assume that if the controller is not bad that the issue is on my truck.





Where exactly beside the plug at the back of the bumper, should I begin?

 

[Cattletrkr]

Try checking the "stoplight" connections. That's one of the four wires going off the back of the controller. It sounds like the controller isn't getting a signal from the stoplight. Could be a bad stoplight switch too.

 

[Billy Golightly]

Thanks Cattletrkr, I'll give that a look this morning and see what I find.

 

[Billy Golightly]

The stoplight wire is receiving no juice to the controller. I found and tested the brake pressure switch on suggestion from another friend and its putting out zero voltage on all 4 or 5 wires I tested. I'm headed into the mopar dealership to see if they have any in stock, the Napa store I usually get my parts at does not.

 

[B.G. Smith]

Have you noticed any lights in the cab not working? Seems I remember when the brake lights lose power something in the cab loses power also to alert you. bg

 

[Billy Golightly]

I just finished replacing the brake light/pressure switch and have got the same problem. I'm about to go over the fuse box with a fine tooth comb, and see what (if anything) I can find. Any other tips on what to look at would be really appreciated, I gotta leave on an 800 mile trip this coming Monday and I haven't even been able to pack or work on my bikes hardly any cause of this brake problem. I shoulda bought one of those Dodge Service manuals on CD from the back of the Geno's catalog a couple years ago...

B. G. Smith: I have not noticed any other lights not working in the cab. The brake lights on the truck and trailer seem to be operating fine, but theres no juice on the brake light wire going to the box. Does anyone know If theres another type of relay or switch somewhere?

 

[B.G. Smith]

I still have a 99 factory manual, it shows fuse #8 in PDC, 40 amp as being for trailer brakes, there is also a relay in there for trailer, it is the one in lower right hand corner of PDC looking over driver side fender. bg

 

[Dieselnerd]

I don't know if your '03 wiring is exactly the same as my '05 but if it is, fuse 24, 15 amp, is blown. This provides the stop lamp signal to your brake controller. I had exact same problem as you on my '05.

 

[jsdan]

yea-bet ya got a blown brake switch fuse ---you sure you got brake lights on your truck?

 

[Billy Golightly]

Thanks for the replies guys, I actually figured out a few days ago but been so busy trying to get ready for the trip I hadn't gotten on here and posted what it was.

Best from I can tell, it turns out that the original brake light switch was working intermittently. I did have brake lights on the truck, and the trailer when wired to it-just no voltage to the brake controller box. The new one I got to replace the original, did not work AT ALL. I got a 3rd one, and all seems to be well now. I thanks a lot for all the input, It definitely helped me diagnose and repair the problem.