Intermittent Brake connection

[mitch]

I'm just back from my first trip of the season and I'm having a bit if an issue with the 7 pin connector.  Although I started the trip with a good connection, at some point I lost the connection to the brake controller.  I stopped at the first rest stop I came upon and pressed the plug in harder and the connection came back.  On the trip home same thing, good connection for about 2 1/2 hours then gone.  I'm pretty sure the lights were still working though.  When I plugged in for the trip home I made sure to plug the connector in very firmly so I don't believe it's a "wiggled loose" problem.  What would be the best troubleshooting approach for this?  I do have a multimeter I'm just not sure what to check exactly, thanks in advance. 

[tincan]

First just a visual inspection.  Make sure all the pins and corresponding holes look correct.  Pins, I have flat blade and slot, all should protrude a equal amount and look undamaged.  The corresponding receiver should look undamaged as well.  Any out of place parts should be corrected.

My 7 pin connector has a protrusion that the cover for the receiver locks/slips over to ensure the plug does not disconnect during travel.

Miss this and it can fall out, trust me on this.  I got to the closest wally world and bought a new 7 pin connector for the trailer and was wireing it in the parking lot.

[mitch]

The visual inspection on the road didn't show anything unusual but I'll check again very closely tomorrow.

[thudd3r]

i had a similar issue where my truck would not tell me the trailer was connected ()which normally happens right away) and the lights wouldnt work (brakes also wouldnt engage)...turned out to be battery from the trailer braking system was low and needed a charge.  once charged everything was good.  this was after the camper had set for awhile without the batteries installed

[swbc150]

I had the same issue when mine was being setup at the Dealer to take home.
Turns out the problem was with the control box injuction with the LL/loose connection and a broken wire.

[peislander]

[quote source="/post/10999/thread" timestamp="1431914360" author="@tincan"]
My 7 pin connector has a protrusion that the cover for the receiver locks/slips over to ensure the plug does not disconnect during travel.

[/quote]
Mine has the same and it can be really difficult to get the plug pushed in as far as it is supposed to be. The flimsy bracket we have holding the female end on the tow vehicle doesn't help and the fact that it is usually so plastered in road grime adds to a reluctance to get the job done. Based on mine, I can imagine lots of trailer users likely aren't getting theirs fully inserted.

[whoofit]

Might want to get rid of those quickie IDC connectors in your brake lines as a precaution. IDC works great for a while then corrosion builds over time. I just don't trust them in wet locations. Especially in braking. I soldered them and used inner-melt heat shrink tubing for a better long term solution.

[mitch]

[quote source="/post/11004/thread" timestamp="1431921319" author="@thudd3r"]i had a similar issue where my truck would not tell me the trailer was connected ()which normally happens right away) and the lights wouldnt work (brakes also wouldnt engage)...turned out to be battery from the trailer braking system was low and needed a charge.  once charged everything was good.  this was after the camper had set for awhile without the batteries installed[/quote]I wouldn't have thought that the emergency battery would do that but I'll check mine, thanks.

[mitch]

[quote source="/post/11005/thread" author="@swbc150" timestamp="1431926604"]I had the same issue when mine was being setup at the Dealer to take home.
Turns out the problem was with the control box injuction with the LL/loose connection and a broken wire.[/quote]Are you referring to the control box junction where the connector mates up to the truck or where the other end of the cable connects at the trailer?  

[wingsoverwisconsin]

I had a different version this weekend.  When I was coming out of the campsite I had crazy 100% trailer brakes.  They would lock up instantly.  The problem went away in a few minutes.  I know my house battery was low but I'm not sure if the brake battery is in parallel.  My guess right now is the low battery was the cause and after a few minutes I got enough juice off the truck circuit to charge it up.  Any other opinions?

[pinstriper]

[quote source="/post/10997/thread" timestamp="1431913531" author="@mitch"]I'm just back from my first trip of the season and I'm having a bit if an issue with the 7 pin connector.  Although I started the trip with a good connection, at some point I lost the connection to the brake controller.  I stopped at the first rest stop I came upon and pressed the plug in harder and the connection came back.  On the trip home same thing, good connection for about 2 1/2 hours then gone.  I'm pretty sure the lights were still working though.  When I plugged in for the trip home I made sure to plug the connector in very firmly so I don't believe it's a "wiggled loose" problem.  What would be the best troubleshooting approach for this?  I do have a multimeter I'm just not sure what to check exactly, thanks in advance. [/quote][p]How do you know you lost connection to the controller ? What were the actual symptoms that lead you to this ?[/p][p]
[/p][p]Also, what controller ?
[/p]

[swbc150]

[quote source="/post/11017/thread" timestamp="1431951470" author="@mitch"][quote source="/post/11005/thread" timestamp="1431926604" author="@swbc150"]I had the same issue when mine was being setup at the Dealer to take home.
Turns out the problem was with the control box injuction with the LL/loose connection and a broken wire.[/quote]Are you referring to the control box junction where the connector mates up to the truck or where the other end of the cable connects at the trailer?  [/quote][p]The wire control box at the trailer (mine is mounted on the frame under the RV Battery).[/p][p]
[/p][p]Also, others may need to upgrade their 7 pin plug connector on the TV to the type that comes standard on most full size pickups. My 7 pin plug connector is spring loaded and has a built in tab to keep the trailer end plug tight into the TV plug connector. Once plugged in it will not work loose.
[/p]

[mitch]

[quote source="/post/11022/thread" timestamp="1431960207" author="@pinstriper"]

I'm just back from my first trip of the season and I'm having a bit if an issue with the 7 pin connector.  Although I started the trip with a good connection, at some point I lost the connection to the brake controller.  I stopped at the first rest stop I came upon and pressed the plug in harder and the connection came back.  On the trip home same thing, good connection for about 2 1/2 hours then gone.  I'm pretty sure the lights were still working though.  When I plugged in for the trip home I made sure to plug the connector in very firmly so I don't believe it's a "wiggled loose" problem.  What would be the best troubleshooting approach for this?  I do have a multimeter I'm just not sure what to check exactly, thanks in advance. 

[p]How do you know you lost connection to the controller ? What were the actual symptoms that lead you to this ?[/p][p]
[/p][p]Also, what controller ?
[/p][/quote]I use a Prodigy P2 controller, I know when it's connected because the display will show a C, when it's not it shows a period.  So I started out with a normal C display, sometime during the trip I glanced at the controller and the C was gone, only a period.  Once in a safe spot I tried to use the manual brake lever on the controller to see what that would do and the display read NC for Not Connected.  

[mitch]

[quote source="/post/11026/thread" timestamp="1431962561" author="@swbc150"][quote source="/post/11017/thread" timestamp="1431951470" author="@mitch"]Are you referring to the control box junction where the connector mates up to the truck or where the other end of the cable connects at the trailer?  [/quote][p]The wire control box at the trailer (mine is mounted on the frame under the RV Battery).[/p][p]
[/p][p]Also, others may need to upgrade their 7 pin plug connector on the TV to the type that comes standard on most full size pickups. My 7 pin plug connector is spring loaded and has a built in tab to keep the trailer end plug tight into the TV plug connector. Once plugged in it will not work loose.
[/p][/quote]The plug really isn't working loose, I'm leaning towards a wire somewhere but the TT plug end is sealed rubber so I don't think a wire would work loose there, I'll check the junction box but again the wire leading into the junction box is very securely fastened so if a wire worked loose it's not from being pulled around. Could be vibration I guess. I'm also charging the emergency battery but I don't think that was the culprit, the battery read read 12.57 volts on a meter which is reasonable.

[mitch]

Opened up the junction box on the trailer, everything looks brand new and feels as tight as could be.  Moved on to the truck receptacle, that looks nice and tight also.  I cleaned up the metal connectors on both ends and squeezed the trailer side connector ends closer together, maybe it's just surface corrosion.