Trailer brake issue
Thread Starter
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Mountain Pass
Joined: Jun 2018
Posts: 152
Likes: 32
Trailer brake issue
Hey all,
I have a 97 f350 single rear wheel with a 7.3 and am towing a 36' fifth wheel. I currently have a Tekonsha Voyager brake controller that was on the truck when I bought it 10 years ago. When I initially used ti to tow my first trailer, the brake controller worked ok. Recently the brake controller seems to be malfunctioning when I tow. Sometimes when I hitch up the trailer and do a brake test by manually applying the trailer brakes, I get no response. Other times the trailer brakes will lock up when I am braking normally. I also get the trailer brakes jerking when I get to slower speeds almost like the are going on and off. Before anyone says it may be the trailer, I have tried towing 2 other trailers both of which have presented the same issues. The light on the top of the brake controller lights up so I know it recognizes that a trailer is plugged in and I also have checked all the wiring coming off of the brake controller and it seems to be in order.
My question is do these controllers go bad? Is there a way to test it before dumping money into a new one? I am tempted to get a higher end controller and really like this one but again, I don't want to drop that kind of dough if the brake controller isn't the issue. Any help is greatly appreciated.
I have a 97 f350 single rear wheel with a 7.3 and am towing a 36' fifth wheel. I currently have a Tekonsha Voyager brake controller that was on the truck when I bought it 10 years ago. When I initially used ti to tow my first trailer, the brake controller worked ok. Recently the brake controller seems to be malfunctioning when I tow. Sometimes when I hitch up the trailer and do a brake test by manually applying the trailer brakes, I get no response. Other times the trailer brakes will lock up when I am braking normally. I also get the trailer brakes jerking when I get to slower speeds almost like the are going on and off. Before anyone says it may be the trailer, I have tried towing 2 other trailers both of which have presented the same issues. The light on the top of the brake controller lights up so I know it recognizes that a trailer is plugged in and I also have checked all the wiring coming off of the brake controller and it seems to be in order.
My question is do these controllers go bad? Is there a way to test it before dumping money into a new one? I am tempted to get a higher end controller and really like this one but again, I don't want to drop that kind of dough if the brake controller isn't the issue. Any help is greatly appreciated.
Hotshot
Joined: Jan 2010
Posts: 10,060
Likes: 491
From: Bristol, TN.
First of all, yes they can go bad. I had one in the past that got erratic. I replaced it. As to testing it, if you have an emulator with the long cord, you can literally plug it in and drive down road and you can watch the output on meters noting voltage and amp draw. It is kind of pricey to buy something like that for a single use and it does sound like your controller is reaching the point of retirement. I am assuming here that the brakes at the wheels and the connections to them are all in good condition and you are not experiencing an erratic grounding issue, however given you have had the same experience with other trailers, that seems unlikely. One other possibility is the connections to your controller in the cab have been attacked by wire eating rodents. Might be worth eyeballing just to be sure. One option you would have would be to borrow a friend's controller, but again kind of a PITA.
In general I think you would be happier with one of the new electronic controllers. Good luck.
In general I think you would be happier with one of the new electronic controllers. Good luck.
Thread Starter
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Mountain Pass
Joined: Jun 2018
Posts: 152
Likes: 32
Thanks for the advice. I have checked and double checked all the wiring under the dash and it seems to be in perfect condition. I also have replaced the plug receptacle on the rear of the truck making sure all the connections were clean, tight and free of corrosion. From reading a couple of other online articles, it seems that the Voyager is the cheapest on price and quality especially considering when mine might have been installed. The guy I bought the truck from was the second owner and he did say that the brake controller was installed when he bought it. This would put the installation sometime between 1997 and 2007 so the unit is at least 16 years old. Definitely time for a new one.
I ordered off Amazon and will install it soon. Apparently it works more like the factory ones installed in the newer trucks and is the best option for magnetic electric trailer brakes. At over $200 it had better be good. It also has a bunch more settings which allow for more precise control. I will try to come back and post a follow up review about this product since I can't find many online reviews at the moment.
I ordered off Amazon and will install it soon. Apparently it works more like the factory ones installed in the newer trucks and is the best option for magnetic electric trailer brakes. At over $200 it had better be good. It also has a bunch more settings which allow for more precise control. I will try to come back and post a follow up review about this product since I can't find many online reviews at the moment.
Thread Starter
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Mountain Pass
Joined: Jun 2018
Posts: 152
Likes: 32
I never really like the Voyager as it seemed to be limited on control and function. It was on the truck when I bought it and worked ok so I didn't see a need to replace it. I agree that Tekonsha makes the best ones out there and this new one is their top of the line model with a lot of built-in technology. The Voyager is Tekonsha's basement model meant for basic use. When I first started towing with my truck I only had a 26' trailer and took it out about 6 times per year. With my new fifth wheel being much larger and going out twice per month, I want to be sure I am investing in a better brake controller for sure. I also spoke to a service manager at Camping World who informed me that many of the cheaper brake controllers don't work well with the newer trailers because the technology on the brakes is improving. He recommended the one I just ordered (Tekonsha 90920 Prodigy iD). He also said that they used to install the Voyager on customers vehicles and stopped about 4 years ago. They now only install digital ones. The Voyager is too outdated.
Hotshot
Joined: Oct 2015
Posts: 19,726
Likes: 12,873
From: Wyoming
I used a Tekonsha Prodigy on my half ton truck. That brake controller was amazing.
As far as your issues goes, I would double check all the wiring, both on the truck and the trailer. There have been a couple posts lately where the wiring was at fault. Fixing wiring is cheaper than a new controller.
As far as your issues goes, I would double check all the wiring, both on the truck and the trailer. There have been a couple posts lately where the wiring was at fault. Fixing wiring is cheaper than a new controller.
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Lead Driver
Joined: Jun 2005
Posts: 8,475
Likes: 728
From: Calgary Canada
I have owned a tekonsha voyager, and to be honest, it was never very good. Tekonsha Prodigy is leaps and bounds better.
I HATE diagnosing electrical equipment, but as mentioned above, much more common to be a wiring connection issue than an issue inside the electronic component itself. So, start finding the loose connection, because a new controller won't solve that.
I HATE diagnosing electrical equipment, but as mentioned above, much more common to be a wiring connection issue than an issue inside the electronic component itself. So, start finding the loose connection, because a new controller won't solve that.
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Hotshot
Joined: Jan 2010
Posts: 10,060
Likes: 491
From: Bristol, TN.
The sngle thing that pointed me in the direction of the controller was the OP's statement that at times the brakes locked up during normal application. I am not sure that can happen with a fault in the wiring. Guess we'll see. I believe his Voyager may be a time delay controller so he will be way ahead in terms of the action of the controller he ordered. 
Thread Starter
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Mountain Pass
Joined: Jun 2018
Posts: 152
Likes: 32
UPDATE:
I installed the new brake controller and towed the 5th wheel home from storage. WOW what a difference! If you have not used or seen the new Prodigy unit, it connects to your phone and you can adjust all the settings using your smartphone. This makes it super easy to fine tune the settings and the unit is adaptive. It will also store several settings in case you tow different trailers with the same vehicle. Mine is set on the highest setting since my trailer weighs over 40% more than my tow vehicle. It now applies the trailer brakes super smoothly with no jerking or sudden low speed braking.
I also forgot to mention that there was a "chirping" coming from the trailer brakes when applied. This unit has eliminated that making me think that the old unit was not applying the brakes evenly. Much better and much more confident towing such a heavy rig. If you are looking for an amazing brake controller, this is your best bet!
I installed the new brake controller and towed the 5th wheel home from storage. WOW what a difference! If you have not used or seen the new Prodigy unit, it connects to your phone and you can adjust all the settings using your smartphone. This makes it super easy to fine tune the settings and the unit is adaptive. It will also store several settings in case you tow different trailers with the same vehicle. Mine is set on the highest setting since my trailer weighs over 40% more than my tow vehicle. It now applies the trailer brakes super smoothly with no jerking or sudden low speed braking.
I also forgot to mention that there was a "chirping" coming from the trailer brakes when applied. This unit has eliminated that making me think that the old unit was not applying the brakes evenly. Much better and much more confident towing such a heavy rig. If you are looking for an amazing brake controller, this is your best bet!
Tuned
Joined: Feb 2020
Posts: 476
Likes: 91
From: Owen Sound Ontario
I will add that I run the prodigy as well and have nothing but good things to say about it. I do not have the fancy version but rather the old bare bones version and it works excellent. Only beat by the factory brake controller in my F-350 but it's hardly fair to compare to that since it is pressure based.
Thread Starter
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Mountain Pass
Joined: Jun 2018
Posts: 152
Likes: 32
Ya get what ya pay for. My brother in law asked me to install the cheapest brake controller he could find at Walmart. It worked well for about 2 years before conking out. I know most of the Tekonsha products are pretty good but some are better than others. The one I went with is supposed to be the best aftermarket one right now since it is adaptive to uphill vs downhill driving. Not sure about longevity since it's a fairly new product but we will see.