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Old 09-15-2011, 11:58 AM   #1
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Trailer Disconnect

I had been experiencing some occasional "trailer disconnected" messages from the built-in brake controller on my Ford F-250 when pulling my old trailer. I understand that the Ford brake controller is a bit sensitive to bad connections. Wiggling the connector and re-seating it on the truck bumper would resolve the issue.

The problem happened much more frequently with the new Crusader. I've noticed that the 7-pin plug from the trailer doesn't fit into my truck's receptacle very well -- doesn't seem to engage the pins all the way and pulls out very easily. On our trip home, I ended up wedging a 1/4 inch piece of wood between the connector and receptacle retention pins (on the receptacle cover) and holding it in place with a bungee. Once home I compared the trailer connector to a couple I had around the garage. The connector on the trailer looks to be a full 3/8-inch shorter than the others I have. Thinking I may need to chop it off and replace it. Has anybody seen a similar issue with their PT trailer?
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Old 09-15-2011, 09:25 PM   #2
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I've not experienced that. But if I had, I would get it taken care of immediately. It seems too dangerous to travel with a connector that won't stay seated. It's more than just running and brake lights. It's brakes.

It is unfortunate that you have to resort to wedging a piece of wood in there. Something is wrong. Good luck resolving this issue. Wish I could provide some guidance.
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Old 09-15-2011, 09:35 PM   #3
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Agreeing with Ovair, that is extremely unusual but needs to be figured out. Let us know if we need to replace a defective Bargeman plug.

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Old 09-15-2011, 09:38 PM   #4
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My truck plug and the trailer plug were not a good match. They were supposed to be however the trailer plug would not go far enough in to lock with the cover. I bought a matching set of CURT truck/trailer plugs and replaced them both as soon as I got home with the new trailer.
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Old 09-26-2011, 11:00 AM   #5
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Further investigation and problem solved.

Bill C seems to have summed it up pretty well - the stock trailer plug just did not fit into the stock Ford socket. It seemed to bottom in the socket with almost no resistance at all; the pins must have been barely touching. I cut it off and replaced it with a Hopkins plug from Walmart. Just pulled 650 miles this weekend with no issues at all.
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