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I had an interesting TBC issue on my SD. When applying the brakes with the brake pedal- no issues. If I pressed the manual switch on the TBC I would get the message "trailer disconnected" but the trailer brakes worked. Got to checking and found a ground wire had broken off of one of the brakes.
Interesting that the TBC didn't show an issue when applying the trailer brakes.
I had the exact same issue with my 2023 F350. Turns out the trailer had a worn out brake magnet. My 2019 F250 didn't care and had no issues with the same trailer. Put new magnets in the trailer brakes and it was back to good with the new truck.
SSM 52363 2023-2024 F-Super Duty - Trailer Disconnected Message
Some 2023-2024 F-Super Duty vehicles equipped with a trailer brake control module may exhibit a Trailer Disconnected message after cycling the ignition off and back on with a trailer connected. This may be due to the presence of an integrated battery charger on a trailer equipped with electric over hydraulic brakes. If trailer functionality is restored after unplugging and plugging the trailer connector back in while the ignition is on, this condition can be corrected by downloading and performing the Trailer Brake Configuration application using the latest version of the Ford Diagnosis and Repair System (FDRS) diagnostic scan tool. For claiming, use causal part 19H332 and applicable labor operations in Section 10 of the Service Labor Time Standards (SLTS) Manual.
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