Two different trailers, flat bed & 5W, tested as you said zero volts to the trailer brake circuit, all lights work as the should.

 

Bad fuse
Bad relay
Bad controller
Bad wiring

 

All factory and the tow fuses I can find #30 in the kick panel, #62 under the hood. Bad relay? Where? I went through all setting in the dash and they all look good. Pulled the flat bed with the wife's F150 and at 4 it locks the trailer brakes but she has an after market controller not Factory installed. The 5W is electric over hydraulic and I could hear the pump with the slider open, now nothing which led me to checking fuses etc. Squeeze the controller in my 2022 and I get trailer disconnected and I know the brakes are not working , zero drag when I use the trailer brake. I have about 25,000 mile pulling this 5W with this truck. I'm still under warranty so if it's a controller or wiring Ford gets it next.

yes it does tech bulletin; Tech bulletin

 

So the saga continues. I took the truck to a dealer all most 200 miles from home when the clsoest dealer 80 mile away said it would be the end of August before they could get me in. Of I go when the 200 mile dealer says I can take you next Friday. I dive over and the they start the work order, mileage is 36,057. We are sorry the bumper to bumper is only 36,000 your out for warranty. 57 miles over.
Had the 80 mile dealer been able to get me in I would be OK but the 200 mile drive put me over. I call customer service, sorry your out. I want a supervisor and they have one call me. He listens to me and says you out I'll see what I can do and call you back.. He did call back, he talked to his supervisor and there is nothing we can do. You can write Ford and explain and they can reimburse you for any expenses you pay if the want to nothing we can do. Six hours later the brake control modules bad we need to order one be here next week, six hours to tell me what I suspected when I drove in.

I'm told they have no recalls, guess I need to print this and take it to the dealer when I pickup the truck. I was smart enough to have my wife follow me over as I knew they would take awhile to diagnose and we would have transportation, no loaners and I might be able to get a rental.

 

Call Ford's customer service and explain the dealerships taking forever to get you in and you HAD to go over warranty just to get in to the nearest quickest dealer near you. Probably get an extra 36k mile bumper to bumper out of it.

 

There IS a recall on the brake controller. View this: https://fordauthority.com/2022/04/fo...-safety-issue/

 

Thanks I had read that and was looking for the letter/recall/Tech Bulletin to take when I go back for my truck. Non of the number listed in the article are ones I called, I'll try those on Monday. Not sure this is the same isue, that appears to be a programing issue where mine is a complete failure of the brake control module.

Found the bulletin:
Equipment Safety Recall 22S38
Certain 2021-2022 F150
Trailer Brake Controller Kits

 

Got any updates?

 

I’m curious as to whether or not you found a solution. I had the problem come up on my 2022. I discover it would happen on the second (or third … I can’t remember for certain) brake application. That is I could just sit stopped and touch the brake. First time no message but if I momentarily released the brake and subsequently reapply it I get the message. (This same thing occurred while driving but because it happened stopped and always on the subsequent brake application I knew it wasn’t a bad connection) Also having the trailer disconnect message illuminate did not mean there was anything on the trailer that wasn’t working. The electric brakes function even with the message displayed. The solution for me was to set my brake control to electric brakes rather than electric over hydraulic. The electric over hydraulic setting makes virtually no difference to how the brakes function anyway. I believe the only difference is that if you are stopped with your foot on the brake pedal at a red light or waiting for a train the electric over hydraulic will stop sending current to the hydraulic pump where as with the electric brake setting you’d have to shift to park if you were concerned about the hydraulic pump running for an extended time. I still have the same trailer but my 23 F350 works with the brake controller set to electric over hydraulic. Also I hooked my brothers 2022 to my trailer and it functioned the same as my ‘2022.

 

There is a connection near the spare tire under the bed that gets corroded. There is also a TSB about the brake controllers on some trucks.

 

I brought my ‘22 in for the TSB. It didn’t fix my “trailer disconnect”issue. Running on the electric brakes setting even when using disc brakes solves the issue.