Prodigy brake control maxed at 13, very little brakes

[Bug Out]

I was coming home today from the national forest about 100 miles north of Phoenix, and tested my brake controller without using the truck brakes.

I had a "oh-boy" type slow down on the way up there friday morning; low boy tractor with a HEAVY load going down (N/B) Camp verde I-17 at 5-10 mph and no one would let me in the #1 lane to get around him, until the last minute. ( its a 6% grade for a few miles)

I discovered my Prodigy brake controller, even maxed out @13 and on b3( boost ) gave me little brake at all. I have a 3 axle trailer.

I dont believe the brake shoes are THAT far out of adjustment. I have checked the wires recently, and all looked intact.

What else might cause that?

I checked and could not find much help in the way of trouble shooting that particular brake controller. I bought it in the 2001-2003 time frame if i remember correctly.

I'm not getting "flash codes" as one post put it.

Where can I find some practical trouble shooting steps to take? I looked at Tekonsha, but there was little info on problems, unless your installing new.


Thanks for the help in advance.

 

[Hoefler]

I would adjust the brakes, might be surprised how far they are out.

 

[HBarlow]

That often results from corroded or worn contacts in your male and female connectors.

Personally, I wouldn't use a Tekonsha Prodigy for a paper weight. Buy a good brake controller and experience the huge improvement in trailer braking.

 

[AMink]

Check your brake adjustment. Mine are too loose and I have to run at about 9 on level 3 to get anything. Not the Prodigy's fault. I find the Prodigy to do a very good, predictable job when things are adjusted correctly. I'd like to try a Brakesmart or one of the other "good" controllers. Just not in my budget at this time.

 

[NIsaacs]

Since they work a little I would say the power is getting through the plugs. Jack up each and every wheel and while you turn the tire have someone hit the controller. That way you can find out which ones work. If you hear the magnet and shoes trying ,but weak stop, probably adjustment. If no noise or drag it might be the magnet or wiring. Then trouble shoot from there.



Nick

 

[KLauber]

The brake controller is doing its job as good as it was designed for. The newer ones are better. The hydraulic ones are supposedly the best but you pay for it. Maintenance is the key.

Ken

 

[Bug Out]

I'll check the brake adjustment first. the Prodigy was the "Top Dog" back when i bought it, among that type of controller.



I'll have to look around and see whats new out there too.



thanks for the help.



Ed

 

[seafish]

You want to do a search here on TDR on both the Brakesmart controller and the Max Brake controller. they both use a hydraulic pressure sensor that Tees into your brake master cylinder and then converts that through the controller into electrical output to your trailer brakes. They are very easy to install, almost plug n'play, and are simply the BEST and most accurate brake controllers out there. Anyine who tries one cannot believe the differrence in driving/braking as compared to ANY other type of controller. Unfortunately, the Brakesmart was bought out by DR. Power and is no longer being manufactured, but you should read some of the threads anyway just to check them out for driving feedback.



Here is one on the BrakeSmart that includes my install and photo at Post #49 at the end of the thread--



https://www.turbodieselregister.com/forums/towing-hauling-rv-forum/90158-brakesmart-controller.html



Here is one on the Max Brake --

https://www.turbodieselregister.com/forums/towing-hauling-rv-forum/222857-max-brake-impression.html



Someone here on TDR sells the Max Brake and has very good customer service too. I believe that their handle is: Dirrgang

 

[MAshley]

I believe from memory electirc brakes on a trailer need to be adjusted every 5,000 miles... . So knowing that brakes wear, as opposed to being like a tv being on or off . . during those 5,000 miles your brakes are slowly getting worse...

 

[RCorbeil]

Check the grease seals in the drums, may be that grease is on the armature plate and the magnets are sliding on a film of grease instead of grabing onto the armature plate.



Ron

 

[GAmes]

Check the grease seals in the drums, may be that grease is on the armature plate and the magnets are sliding on a film of grease instead of grabing onto the armature plate.



Ron

That was my thought. Do you have EZ lube hubs and did you pump grease into them?

 

[Bug Out]

Actually, I just repacked the bearing/new seals etc and all is well in that dept. I did check the adjustment today and each star adjuster( I don't know if there called that anymore-1970's verbage) was about 2+ turns out before the wheel would begin to slow or show the shoes rubbing.

I did not have a opportunity to test them. I'll do that Thursday. Hopefully thats all it is. I rarely ever use the brakes as the truck exhaust brake does 80-90% of the stopping. The shoes had 70-75% left on them before i went on a trip in June this year.

Thanks for the tips and info.

 

[Grizzly]

You want to do a search here on TDR on both the Brakesmart controller and the Max Brake controller. they both use a hydraulic pressure sensor that Tees into your brake master cylinder and then converts that through the controller into electrical output to your trailer brakes. They are very easy to install, almost plug n'play, and are simply the BEST and most accurate brake controllers out there. Anyine who tries one cannot believe the differrence in driving/braking as compared to ANY other type of controller. Unfortunately, the Brakesmart was bought out by DR. Power and is no longer being manufactured, but you should read some of the threads anyway just to check them out for driving feedback.



Here is one on the BrakeSmart that includes my install and photo at Post #49 at the end of the thread--



https://www.turbodieselregister.com/forums/towing-hauling-rv-forum/90158-brakesmart-controller.html



Here is one on the Max Brake --

https://www.turbodieselregister.com/forums/towing-hauling-rv-forum/222857-max-brake-impression.html



Someone here on TDR sells the Max Brake and has very good customer service too. I believe that their handle is: Dirrgang

I agree on getting a MaxBrake. I have the BrakeSmart, but you can't get these anymore. World of difference between these and anything else.



george

 

[steved]

I have towed a lot of miles and many trailers on my Prodigy in several trucks... only had one occasion with an issue like this.

It was because the trailer MANUFACTURER had used scotchlocs on all the connections and they had POOR connection and had CORRODED because they are not weather-proof, let alone weather-resistant. This in turn would not allow full voltage to be transmitted to the brake actuators (so how is your BrakeSmart or any other controller going to fix this??).

I would start at the wheels and move forward to the controller... not the other way around.

 

[seafish]

Steved, I don't think that anyone here is saying that hydraulically actuated brake controllers will solve a problem involving bad trailer wiring. And you are absolutely correct, ScothLoks on brake wiring (or ANYWHERE imho) are an electrical problem just waiting to surface. Perhaps this was NOT the right thread to bring up the advantages in brake control of these new type of controllers, but the fact remains, that anyone who uses them instantly recognizes the advantage of them in terms of completely nuanced brake pedal control of the trailer brakes. I was for MANY years completely satisfied with using my old DrawTite, inertia type brake controller, but when it was time for a new one, based on what reading here, I opted to purchase a Brake Smart. I would NEVER go back, and it is not because I drank some sort of TDR made, brake fluid laced Kool-Aid :-laf, but simply because they are a vastly superior product then even the highest-end, best made inertia type controllers. Does everyone want or need a superior brake controller?? Probably not, but I for one, would not want to tow with anything else anymore. I do hope that the OP is able to fix his braking problem with some of the excellent advice being offered here.

 

[steved]

There are at least three posts here that indicate its an inferior brake controller problem, and that the "far superior" BrakeSmart would basically solve the problem...



Just what the OP needs... to be told his brake controller is faulty, pay good money to replace it with a "superior" product, only to have the same problem, and find its a $0. 50 connector on the trailer.

 

[MAshley]

Wow that just reminded me ... I had the same thing Scotch locks but they came undone and the way they wired the brakes up I only had one axle working out of 2 on a 14,000 load... I agree and second the start at the axles and move forward in checking...

 

[steved]

Wow that just reminded me ... I had the same thing Scotch locks but they came undone and the way they wired the brakes up I only had one axle working out of 2 on a 14,000 load... I agree and second the start at the axles and move forward in checking...

I towed my M37 home from New Mexico using a borrowed trailer... it had ONE working brake out of four. The ONLY way I knew I had a problem prior to even loading the M37 was that my brake controller indicated an intermittent issue with the brake wiring. I ended up rewiring the entire brake system in a hotel parking lot. The 2100 mile trip home was uneventful thanks to an hour with new wire, heat shrink, and a soldering iron.



This was the first, but not the last trailer I found with faulty wiring. In every instance, I have found faulty wiring to be the cause of poor/no braking in my experience.



My Down-to-Earth had less than 200 miles on it before a complete rewired... preventative maintenance goes a long way. I counted no less than ten Scotch-Locs. Same with my 5vr. I put less than 25 miles on it before rewiring a working brake system... it had Scotch-Locs and crimped connectors all over the place.

 

[DennyDay]

New MaxBrake

Well, put two new axles on the trailer - - 6 lug and new 16' wheels so I bit the bullet today and ordered a max Brake - - i sure miss the old Kelsey Hayes

controler that was connected to the master cylinder - - hope this works as wellOo. Oo. Oo.

 

[LBARTLETT]

i

sure miss the old Kelsey Hayes

controler that was connected to the master cylinder - - hope this works as well

This will be as close as anything you'll find, I messed around with 3 or 4 different controllers before I bit the bullet and bought a max brake, I left it on my 01' for the fine young man who bought my truck, I ordered one for my new to me 06' today



I really miss the old Kelsey Hayes too, they worked like a charm