Trailer brake controller

[JMA1181]

I was driving down the road pulling a trailer. Everything was fine and then all of the sudden it said trailer disconnected. The trailer was not disconnected as I got out and checked it, trailer lights were still working. I take it in to the dealer and they say everything is fine because they can move the lever over and it lights up, they have no way of testing it. I told them it wasn't because the brakes don't work. I have hooked it up to three different trailers and have the same problem. The tbc doesn't light up when a trailer is hooked up to it but the lights work on the trailer. I have hooked up another truck just like mine to all of them and there is never an issue. If I push the lever over, the controller lights up like nothing is wrong. In the end the dealer tells me that everything is fine but if its not, then I need to replace the tbc which cost $500 for parts and install. Anyone else ran into an issue like this?

[kawboy2020]

Mine does the same thing, trailer shop said Ford TBC is crap....way too sensitive. He advised me to buy a good quality aftermarket controller. FWIW

[JMA1181]

Originally Posted by kawboy2020

Mine does the same thing, trailer shop said Ford TBC is crap....way too sensitive. He advised me to buy a good quality aftermarket controller. FWIW

In the past 4 years I have owned two trucks with the TBC on them and I love them. I have driven many other trucks with them as well. I would never buy an aftermarket controller again. I had a truck with an aftermarket controller on it and it sucked. Everyone I have talked to that has had the TBC around here loves them too. I don't see how they are too sensitive, you set your gain and the output is determined by the amount of pressure you put on the pedal. I am not saying that he is wrong but you should also consider your source. A Dodge salesman is going to put down a Ford any day, thats how they try to make their money.

[Fantom]

Is it possible that it's not the TBC itself, but maybe some rust on one of the pins at the back of the truck? Maybe try replacing the plug before spending $500 for a new TBC.

[MikeThompson]

I have the same problem with mine, except it's intermittent. Just happens at random times, lights still work, but no brakes. I've traced everything on the truck and RV and can't find the problem. My 05 never had an issue, but the 06 does. It's not an issue yet, but we're going to the southwest this summer and I don't want to be going up and over the Rockies with no brakes. If I can't find the problem, I'll buy another Prodigy controller.

[JMA1181]

Originally Posted by Fantom

Is it possible that it's not the TBC itself, but maybe some rust on one of the pins at the back of the truck? Maybe try replacing the plug before spending $500 for a new TBC.

It is very possible but the plug looked fine. We put some grease on it and it didn't help any. The dealer says they have no way of testing it other than pushing the lever over and seeing it light up and them saying its fine. I am taking it in to another dealer to get my smart junction box replaced so I will have headlights again and they deal with a lot more trucks so they will take a look at it as well.

Mike Thompson: My problem was also intermitent and then it quit working so I would be a little leary of it. Not saying the same will happen to you, but it is a possibility.

[MikeThompson]

Originally Posted by JMA1181

It is very possible but the plug looked fine. We put some grease on it and it didn't help any. The dealer says they have no way of testing it other than pushing the lever over and seeing it light up and them saying its fine. I am taking it in to another dealer to get my smart junction box replaced so I will have headlights again and they deal with a lot more trucks so they will take a look at it as well.

Mike Thompson: My problem was also intermitent and then it quit working so I would be a little leary of it. Not saying the same will happen to you, but it is a possibility.

Let me know what you find out. Mine may be the same problem.

[Ryanbaker83]

My 05 is doing the same thing. So far no loss of brakes. There is no rhyme or reason for it, but it's getting more frequent. My pigtail is new since the cover broke and wouldn't hold the connector anymore. Would like to hear more input if anyone has had this problem and had it fixed.

[JMA1181]

I still have no answer for this problem other than I quit pulling trailers. The last two days I have been getting a message that says trailer wiring fault. Kind of odd considering there is no trailer hooked up. Anyone have suggestions on this? Gets kind of old listening to the beep driving down the road.

[Ryanbaker83]

Mine ended up being in the trailer. So I don't have a real answer. But a thought, Have you pulled the connector off of the truck and checked the connections on the back side? You may have moisture built up in the back side and causing a short. That would send mixed messages to the controller itself. Also, you may try unplugging the connector out back and see if the problem goes away. Might have a shorted connector. Just some ideas, good luck!