I need some help understanding the operation of the Integrated Trailer Brake Controller.

The Service manual says that the voltage supplied to the Electric Brake pin on the trailer connector should be between 1 - 2 volts with the gain set at 10 and activated with the manual lever(I measure about 2.2v).

How can you apply the brakes on a 12v system if the controller only gives 2.2v ?

I assume the system increases the voltage in normal activation with the machine in motion, but how can you 'lock' the brakes with the vehicle not rolling ?

Thanks

PDG

 

Hang in there pal, somebody will be along shortly with more info.

In the mean time, do a search....there's all sorts of good info that has already been posted. We just need to go back and find what users have shared with us.

 

I did search and have found that the system was supposedly not designed to operate at full voltage to hold the trailer when at less than 15mph or so. However the problem comes in when the DOT wants to pull my Inspection certificate since they test the vehicle to hold at rest, by manually activating the trailer brakes and then pulling against it.

The test bay will not allow them to get to 15 mph. I've BS'd my last time thru the inspection lane. The inspector actually applied the sticker, then threatened to remove it as I was leaving the inspection lane.

I'm sure that others have run into this. Has anyone gotten an answer from Ford ?

I can't afford to be taken out of service while arguing the way the system is supposed to operate.

PDGX

 

After much 'discussion' with the local Ford Dealer - with no real assistance - they sent me a document from the service manual that only shows that it will not allow, at less than 15 mph, to lock the brakes. This was not satisfactory to the local Inspection Lane personnel. They threatened to pull my Inspection certificate if it was no 'fixed'.

I also found that Ford changed their design in mid-2005 build, to go back to allowing the manual brake control to lock the brakes when the machine is not moving, to allow for testing the brakes like the inspectors want to. However Ford would not upgrade the controller to do so. My vehicle was made 6 months before this change was made ! Rather disappointed in Ford for not standing by the product, when they obviously made a running change to address the problem.

However, checking thru another Ford Dealer - who actually knew what a Truck was - got a reference to a website for the 'Commercial Vehicle Safety Alliance' that has a document advising Inspection Lane personnel on the operation of the 2005 Ford Integrated Controller and to not ticket operators, when the system is actually working properly. It also describes in detail what they should be doing to inspect trailers pulled by vehicles with the new Ford Controller.

The Website is - http://www.cvsa.org/ - go to the lower right side of the page to the 'Inspections Bulletins' link, and then to the '2005-01 – Trailer Brake Controller [TBC] 2005 Ford SuperDuty Vehicles ' Bulletin.

I haven't used this yet, as the next Safety Inspection is not until November, but I would suggest if you have an early 2005 SD (check if you can manually lock the trailer brakes with the vehicle not moving, and then pull against it) with the Integrated Brake Controller, you should carry a copy of this at all times, in case you get stopped on a Road Side Safety Check, or for your next Truck Inspection, in case you have inspection personnel who are ignorant of the new technology.

A couple of interesting notes in the documument are "... that inspection programs in some states and provinces are incorrectly ticketing vehicles for inoperative trailer brake systems because they may not fully understand the installed TBC system." and "... no regulation requires a manual brake activator for electric brakes."

Hope this helps someone else as well.

PDG X

 

That is some GREAT information!

 

Been a bit over a year, but I remember seeing a very similar thread either here in the Super Duty forum or down in the 6.0L forum. Regardless, this really needs to find its way into a sticky/tech folder for all of the Super Duty-related forums and down in the Towing forum. Granted, it is not an every day/week/month topic, but it could definitely help out some other members.

 

PDG

THANK you for posting this info. I have a 2005 F350 and I have the shop manuals too. I'm hooked up to my camper tonight ready to go camping in the AM and I ran into this very thing. The BC will not lock the brakes. I just adjusted the trailer brakes and was trying to do a drag test and they will not lock by the pedal or manaul lever either going slow.

I have about tore the system apart making sure every thing is correct and trouble shooting this thing. Standing still I can only pass about 1.5 amps and about 2 volts to the TT brakes. I even hooked up a test light bulb. About .75 amps and 2 volts

The emergency brake away switch applies 10 amps, when I taped into the brake circuit so I know the trailer wiring is sound. I finally hot wired in one
of my older Jordan brake controllers in the dash, pulled the Tow Command unit out and tapped into the power plug even. And everything works thru the truck, thru the 7 wire and the camper. So I was about to go buy a new controller.

The 2005 shop manual does not say squat about not being able to lock the brakes with the manual lever or at any speed. They say if it is passing that 1 to 2 volts it is working OK.

I was already to go out and buy a new controller first thing in the AM and thought I would search here and your post came up. WOW exactly what I have. I'll have to get up to speed a little and then try it.

Thanks again.

FordCamping

 

It tried to follow your link, CVSA

They changed the site setup and I cannot locate that bulliten.

If you log back on pleases advise where you found it with the new looking site

Thanks

 

I think i attached the file for your reference

 

i can not attach but if you pm me your email i will send the pdf to you

 

try this link

CVSA

 

jerzydiver

I got it now. The link works. THANKS a millon. Printing now.

Thanks again

FordCamping