brake controller voltage issues... - Ford Powerstroke Diesel Forum
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post #1 of 4 Old 02-12-2010, 02:11 PM Thread Starter
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brake controller voltage issues...

I have a 2001 F250 PSD and I noticed that my brake controller was no longer working the other day so I purchased a new one. When I went to install it I check the voltage in the factory wire harness for the brake controller and in the blue wire (trailer feed) I was getting 2.4 volts without hitting the brake and when hitting the brake I was only getting approximatly 6.3 volts (all with the truck running.) In the instructions for the brake controller it shows that I am suppose to have 12 volts when brake is pressed and to confirm we checked it on my dads Excursion and it was reading 11.9 volts pressed and 0 volts with no brake. I know there is an issue somewhere I just cant seem to find it and I was wondering whether anyone had any suggestions on how to troubleshoot or has had this issue before.



The brake contoller I purchased is Activator III 1-4 Axle Brake Control - #5520


2001 F-250 Regular Cab Long Bed 4X4 7.3L PSD
Eagle Alloy 1372 16x8 rims with 315/75 R16 American Prospector A/T
2005 emblems/Harley emblems.
MBRP exhaust tip.
Cobra 29 WXNWST CB Radio and 4' Wilson Fiberglass Antenna


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post #2 of 4 Old 02-17-2010, 07:26 PM
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Sounds to me like you have a short in the wire. I would first check the voltage right from the brake controller itself. Test it at the connection to make sure you dont' have a bad controller. Then I would check the existing harness to make sure that it is wired correctly to match your new controller. Its almost like there is somthing crossed to be getting voltage without pressing the brakes unless the controller is bad.

2012 F-250 Crew Cab LB 4x4 OFF ROAD
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post #3 of 4 Old 02-17-2010, 09:29 PM Thread Starter
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There currently is no brake controller hooked up. The issue is with the wire in the factory harness in the truck that supplies the trailer feed. It gives me 2 volts with no brake pushed and 6 when pushed. It should be 0volts not pushed and 12volts when pushed. I believe that it might have something to do with the BPP.


2001 F-250 Regular Cab Long Bed 4X4 7.3L PSD
Eagle Alloy 1372 16x8 rims with 315/75 R16 American Prospector A/T
2005 emblems/Harley emblems.
MBRP exhaust tip.
Cobra 29 WXNWST CB Radio and 4' Wilson Fiberglass Antenna


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post #4 of 4 Old 02-18-2010, 03:07 PM
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in that case I would just run a new wire from the brake controller to the plug on the bumper. Just abandon the old wire

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