Almost two years ago, I file a formal complaint with the NHTSA (National Highway Transportation Safety Association) regarding my complaint of a controller installed in my truck with a build date of March 24, 2005. I found out FORD had issued a TSB that this was a problem, but not a warrantable repair.



Last week I was contacted by the NHTSA and notified that the U.S.DOT/NHTSA would pay to remove and replace this unit if I would take my truck to the nearest Ford garage. I just returned with the new controller installed at no cost to me.



Thank you to the NHTSA. AND, from several conversations, let me tell all members, the FORD TRUCK ENTHUSIASTS FORUM is read by people that can make things happen. Thank you Ford Truck Enthusiasts forum.



March 24, 2007 (my post date)

I have the old controller on my pre March 2005 build date F - 350. As such, the brakes do not work unless you are moving 15 mph + -. To check if that is the controller you have, drive on road and manually apply trailer brakes. At stopped position 1 volt or less goes to brakes. Not a failure, as per Ford. They have a bulletin out that explains in greater detail. I think it sucks, but doesn't suck enough to replace. Allegedly not a problem at a DOT stop, which I truly question.

 

Can you provide more detail on this? I have the older controller as well and am not happy that I can't activate the brakes manually under 15 MPH.

Did Ford install the newer system or an aftermarket controller?

Can you provide me with contact information on who contacted you from the NHTSA?

Thanks and I'm please to read this!!

 

As far as I know, only happened on pre March, 2005 built trucks. Mine was one of them. I spent hundred of dollars rewiring a new trailer, as I was too dumb to believe FORD would do this.
Ford installed a new Ford part, presumably the new type controller. I made the Ford garage use the test trailer plug that showed all systems were functioning. Part of my deal was that I had to personally ship back the old controller. I just presumed that it is the up to date part. I will know in a day or so when I hook up one of my trailers.
I hate to put these numbers in this forum, but, if what you have, is the same as what I had, IT IS DANGEROUS! NHTSA: Robert Esser (800) 262.8309 (ext. 265); Scott Ericksen (ext. 261); and Gary Hewett (ext. 266).
Good luck

 

I talked to the NHTSA. They bought your old unit so that they could figure out how it works and whether or not they should start looking at *all* brake controllers. They stressed to me that there is no investigation yet and no recall planned and that while they're looking at Ford more closely due to all the complaints, they're considering all brake controllers.

So..no one else will get a replacement on the NHTSA's dime.

More to follow.

 

Same question. Two years later. If someone with this controller, gets pulled over for a safety inspection, by a STATE DOT or FEDERAL DOT, will this pass? I have been away from the over the road trucking for many years. But I know damn well, 20 years ago, you had to prove brakes on the trailer. And, you can't do it with that pre March 2005 brake controller. Pure and simple. I am glad I was the test case. No one ever told me that.

 

I assume this is only a problem on the 05 model. Every time I tow my Airstream on my 08, I test the controller pulling out of the driveway. It works manually at any speed. In fact, it works better than any after market contoller I have ever used on my older Ford trucks for the last 20 years.

 

Exposed: You nailed it when you said: "I test the controller pulling out of the driveway". With the pre March 2005 controller you could not test your brakes. Once I understood the problem, I would test my brakes on the road at more than 15 mph, but always a fear.

In the north, it is not uncommon for roads to ice up. My further concern was coming down a steep grade in my home town in PA and not being able to apply the trailer brakes first. Think about it. When would you use the manual brake controller? Going at 10 mph or 50 mph? The answer is obvious. Ford still should issue a recall and fix all the bad controllers, IMHO.

 

i have a 1999 F350 and i need a brake controller to use with my 5th wheel -
so which one is the best for that?

i would rather hear it from ford lovers who have on road experience than a counter person who just wants to make a sale.

 

I have an 05 v-10, and the built in controller is way superior to any after market controller I have ever used. I wouldn't want anything else. I tow a 6500lb travel trailer.

 

Bob Kessler:
I am not knocking Ford controllers built after March, 2005. I am not knocking FORD. I am damn disturbed about my controller on my $55,000.00 MSRP F-350 that had screwed up trailer controls. Why not check your build date, and then speak. My bet is that your 05 was built after March, 2005. Ford acknowledged the problem in a TSB. That just didn't want to fix it. All is documented in this forum, about a year ago.

 

Tekonsha Prodigy. Hands down. Buy it on ebay for around $90 new.

 

According to the NHTSA guys, there are no DOT regs on brake controllers. He was going to check with their compliance department, but was pretty sure there aren't any standing regulations controlling brake controllers. That's part of the problem. He was going to call me back if he found something to the contrary.

 

It seems like you are going to keep going. My suggestion is to talk with someone in your STATE or the FEDERAL DOT Dept. Whoever does road checks. Imagine a tractor going down the road without the air brake controller? It does not make sense. Same as air brakes, but electrical. I personally never went thru a DOT road check. I thought they checked the brakes. In our type controller, a DOT guy is not going to crawl under a little trailer. I just thought they would say, apply the trailer brakes, and pull forward. If I am wrong, GOD help us on the road, because how many small truck trailers are out there with NO BRAKES on trailer at all. WOW!

 

Hm, I didn't get the ford controller, I was bumming on it, but it sounds like there may be some issues .

To second BigZiff - I can recommend a Tekonsha Prodigy, which replaced a Tekonsha Voyager. Easier to set up, way smoother in city driving, and I find it smoother when I'm backing up, it's proportional in reverse too. The voyager isn't a good choice for a heavy trailer.

/trill

 

The Federal DOT brake check rule is for "Commercial" Vehicles with a GVWR/GCWR of 26001lbs or more. There is no DOT brake check rule for private vehicles and RV's are exempt from just about everything.