Trailer Brake wiring issues/tow rig wiring

[Bones]

Bones; I have 2014 Dodge 2500 diesel towing 2011 Big horn. I HAVE THE EXACT PROBLEM you described Going nuts trying to figure it out. Have you for sure solved the problem?? How do you apply this dilectric grease? Is it a spray? JohnOtt P.S. Thank you

I must have missed this post. The grease didn't work but still could help. I think the problem may lie in my electrical connector in the bed. I have two one in the bumper and one in the bed. I drove for 3.5 hours with the trailer connected to the bumper and no issue. My camper is in for repairs now so I should get it back soon to test again. This time I will drive halfway with it connected to the bumper and switch it to the bed connector. I had the truck give me an error code when I had no trailer connected at all. Took it to the dealership and they claimed it was the camper. So all in all I am left trying to chase this thing down. When the weather gets warmer I may drop my spare and pull the harness apart and see if anything is loose at the bumper connector for the bed split off.

 

[Bob&Patty]

Bones, you answered your own question. If you do not any issues when plugged in at the bumper. Then you issue is in the add-on in bed plug. Who installed it and how. Did they splice in new wires or was is a plug and play? Most wire harnesses are a plug and play install kit. Maybe at some point its not plugged together firmly and vibrates loose. Could have a bad terminal that only makes contact at times....pushes out of the plug itself...creating an intermitten open in the circuit. Take it back to who ever installed the harnes and MAKE them inspect their work and product.

 

[jnbhobe]

I have had the same thing happen, it has always been the plug in the bed that turns green. I have to disconnect power and wire brush all the contacts and apply new dielectric grease.

 

[Bones]

Bones, you answered your own question. If you do not any issues when plugged in at the bumper. Then you issue is in the add-on in bed plug. Who installed it and how. Did they splice in new wires or was is a plug and play? Most wire harnesses are a plug and play install kit. Maybe at some point its not plugged together firmly and vibrates loose. Could have a bad terminal that only makes contact at times....pushes out of the plug itself...creating an intermitten open in the circuit. Take it back to who ever installed the harnes and MAKE them inspect their work and product.

Hi Bob, Unfortunately it is not that easy. The company who installed the package was the manufacture when you order the tow package and pucks. The dealer ship only looks at what the manufacture tells them to look at and ultimately blame was placed on the trailer. I tried to tell them that the error came up when I was not even connected but they didn't listen. The instructions were clear from the dealership to run the unit plugged into the bumper then run it plugged into the bed and see if the error code comes back. I was told once the code is set that I have no way to clear the code and that it will always come up on the dash. I disagree with them but I need to follow in-order to prove the truck has a problem and get it covered under warranty.

 

[Bones]

I thought I would circle back and Update on progress. Maybe it will help some one else.
I am still having issues with the brake controller letting go of my trailer. It is extremely inconsistent in when it decides to do it. There is no pattern. The truck chimed only after 5 minutes of being hooked up then stopped after 15 minutes and was quiet for an hour. The truck now comes up with error codes in both the bumper and the bed plugs. The dealership has taken the wiring harness out coated it and states they have checked all connections. On the way home the truck pulled for over an hour and no issue then all of a sudden start chiming with error codes 5 minutes from home. Got it home parked and left it hooked up. We unloaded and then I took the unit to storage and no codes what so ever to storage and that alone was a 15 minute ride.
Things I have done so far trying to chase the the issues down. I have changed some of the wire in the box where the pigtail connects and the grounds. I have ohmed the rear axles and they are roughly 2 ohms each. Found some corrosion on the wire connectors after pulling the chloroplast down. So I pulled out the wires and separated them. Tied the ground wire to the chassis as well as one wire from each axle. Then tied the blue wire to one wire from each axle. This should keep a good connection to the brakes. I have ordered a new pigtail and a new 7 wire junction box to eliminate the wire nuts in that area of the trailer.
The truck is going back in the shop today and I am going to request a new brake controller. This is getting to be a pain in the butt. Doing a lot of work on new stuff that should not have this issue. I have read that there could be a problem with the factory y cable too so I may request a replacement harness as well for the truck but they may not do that.

 

[Bones]

I feel like I am running around in circles. Still trying to find the problem. The brake controller has been replaced. I pulled the camper home and I came up with error codes. So I replaced the pigtail last night with a new one as well as adding one of those fancy 7 pole junction boxes. I checked all of the lights before I called it a night. I spent some time yanking the front axle wires and found a wire that had some of the sheath damaged sliced. Peeled the outer covering back and the weird part is there is another wire under that with another sheath. The wires almost look solid but not sure. I am going to abandoned the wire going through the axle and run two new wires on the outside and strap them to the front axle attaching them both to the brake magnets. This is driving me nutzs and the wife is not too happy. Brand new truck and camper should not have these issues. Frustrated Electrical gremlins are the worst.

 

[justafordguy]

I just got a TBC Fault message on my dash last week just before our trip last weekend. I didn't even have the Gateway hooked up yet. I unplugged all of the wiring to the bed and bumper mounted 7 way plugs and spayed the connectors good with WD40. After I plugged everything back in the message went away. I towed to the lake and back (200 miles) and the fault message never came back on, I'm hoping my problem was just a loose connector.

 

[Bones]

I just got a TBC Fault message on my dash last week just before our trip last weekend. I didn't even have the Gateway hooked up yet. I unplugged all of the wiring to the bed and bumper mounted 7 way plugs and spayed the connectors good with WD40. After I plugged everything back in the message went away. I towed to the lake and back (200 miles) and the fault message never came back on, I'm hoping my problem was just a loose connector.

That is the only thing I have not personally checked. The dealership said that they took all of that apart though.

 

[cookie]

I'm hoping my problem was just a loose connector.

I was not getting any power to my right signal lamps. I tracked it down to the in bed plug. The contacts were spread and not making contact. A little bending and all is good again..
Check yours.

Peace
Dave

 

[Bones]

I was not getting any power to my right signal lamps. I tracked it down to the in bed plug. The contacts were spread and not making contact. A little bending and all is good again..
Check yours.

Peace
Dave

I'll check mine. thanks

 

[Bones]

Well after rewiring the pig tail. I took a look at the front axle. I discovered the wire going through the axle was shorted out. I ran new wire for the axle and then decided to fish out the wire in the axle to look at, this is what I found.



Sooo Do you think I found the problem. Brand new trailer and this is how I got it.

 

[Bob&Patty]

Yep, looks like Lippert strikes again. Get that fixed and your trailer brakes might even work better. When you run the new wires. At least put some split tube at the holes in the axle. Better yet...install some rubber tubing/Hose at that point on the wires.

 

[Bones]

Yep, looks like Lippert strikes again. Get that fixed and your trailer brakes might even work better. When you run the new wires. At least put some split tube at the holes in the axle. Better yet...install some rubber tubing/Hose at that point on the wires.

I sure hope they work correctly, finally. I ran the wire on the outside this time and zip-tied it to the axle. Once I finish my faucet install for the kitchen I will close everything back up and cross my fingers that it all works like it should. You can see the new wires in the pictures. The blue and white are in a wire loom.

 

[justafordguy]

Hey Bones, I'm glad you found your problem but now you got me worried about mine.

 

[Bones]

Hey Bones, I'm glad you found your problem but now you got me worried about mine.

My axles are #17 and 18 out of 25 the date due on the axle is 08/20/14 Both axles look completely different from one another in paint and rust

 

[Bones]

I would say with a total of 22 hours driving that the brake issues have been resolved. Woo Hoo. No chiming

 

[justafordguy]

That's great news.

I noticed that my axles were not made on the same day but they both look the same as far as condition/rust. I'm considering running larger size brake wire from my pin box to the axles and covering it with something to protect it. Seems like there have been several people complain about brake performance and I feel like the wire being to small may have something to do with it even if it's not shorted out like yours was.

 

[Bones]

That's great news.

I noticed that my axles were not made on the same day but they both look the same as far as condition/rust. I'm considering running larger size brake wire from my pin box to the axles and covering it with something to protect it. Seems like there have been several people complain about brake performance and I feel like the wire being to small may have something to do with it even if it's not shorted out like yours was.

The wire from the pin box is heavy enough but the wire in the axle tube is small. I also gave the axles a dedication to the ground on the chassis which is different from the factory. The factory ran a dedicated line for power and ground from the pin box. I can actually abandon the ground going back to the axles if I want but I left it hooked up.

 

[Bones]

Well my great news lasted about 1500 miles and then today on the way home I completely lost all of my trailer brakes again. This is really a PIA and quite annoying. Did quick investigation and the rear axle wiring has burnt up in the same exact place. There has to be something wrong with those axles. I replaced the wire in the front axle, now it looks like I will be on the ground tomorrow replacing the rear axle. Brand new coach and I am on the ground replacing wiring cables. Who the **** put these things together.

 

[rdgt67]

Did you get it resolved?