Originally Posted by Bama Rambler
I've seen it on several trailers, not just RV's.
When someone tells me that the trailer isn't braking hard enough, AND they've checked and adjusted the brakes and wire terminations, then I always suspect the molded on 7-way plug. As I said above, replacing it made a night and day difference on the last few RV's we've owned.
I wish the RV industry had adopted the round pin connectors that the trucking industry uses. They have a lot more contact area and the sockets press around the pins much tighter.
This is what I found...
OK... I finally got around to changing the 7-way moulded on pig-tail end to an after market plug.
Now I will have control of making a solid connection inside the plug.
Prior to taking everything apart I was checking inside the junction box to make sure they were all connected to the corresponding locations.
I noticed that the 'brake wire' coming in was discolored and had a melted spot on the jacket.
Further inspection showed some scorched areas inside the junction box and upon removal of the whole wire assembly revealed that the 'brake wire' had been shorting out for a long time.... way before I even owned the unit.
The metal clamp that holds the wire going into the junction box was partially broken and allowed the large multi cable to vibrate until at some point the brake wire shorted out, causing the outer casing to burn/melt , exposing other wires to be damaged.
All this was a big surprise to me... but, luckily I found it before a fire happened or having no brakes down the road.
- the wires that were going into the junction box (that connect to the truck) revealing the melted casing.
- the New connector that will replace the moulded on one.
- the junction box (scorched) and the clamp that also has some melted metal on it where it was shorting out.
IMO... the clamp that secures the wires going into the junction box probably was "over tightened" squashing the multi-cable. Also I think this probably was done at the factory, as this unit has had very little highway travel before I got it 2+ years ago.
When I reassemble everything I will be placing an extra protective piece of rubber where the clamp tightens around the multi-cable... as a precautionary against squashing and chafe.
Hopefully my braking power will be improved as well.
I posted this not to alarm anyone but only for informational purposes .
'07 WildCat 30 RLBS ~ West Coast Edition ~
Trail Air - Tri Glide Pin Box
2000 F350 Lariat DRW 4x4 7.3 Diesel 87k miles
Edge programmer, 4" SS exhaust turbo/back
Vancouver Island, B.C., Canada