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Old 02-01-2012, 01:02 AM   #1
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Breakaway switch

Hi,
My 2005 SD Ford with factory trailer brake controller and 2005 Wildwood TT sometimes would read “trailer fault/disconnect” when braking. I always got out and checked the 7 pin and cleaned and greased it. My last trip, 1,300 miles it did it just as putting it away.
Today while hooking up and 7 pin connected I pulled the breakaway and put it back in, pulled forward, trailer did not brake, again pulled pin and noticed breakaway fried. Don't know if it happened then, it looked old and smelled no smoke or felt warm. After replacing the Bargman my Ford controller wont illuminate or work. It got dark so I'm reading to check fuses on truck, current supply and path, and lastly magnets and brakes.
THE QUESTION IS: Has anyone fried their Ford controller and had/how to replace it ?? Hopefully I won't be going that route, but I may. Either so I'll post the outcome.
Thank you
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Old 02-01-2012, 03:31 AM   #2
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Oops. Sorry. Am a slow learner

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Timmy ( my kids call me Mr. northAmerican or aka BBD ),
JJ, ( both of us aka Yogi and Boo Boo )
Lucy and Sophie ( a Ranger once called 'em Napoleon and Bin Laden ) ...c'mon you gotta laugh they weigh 4 1/2 lbs. and 11 lbs.

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Old 02-01-2012, 08:09 AM   #3
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Hey brother. I'm not sure if this relates or not, but when I first got my camper, I used to hook up and plug in while my truck was running. And I would get a fault reading on my brake controller. When I shut the motor off, then unplug/plug it in again, then start the motor up again, all is just fine. Not sure if this makes sense or not. Really tired this morning......lol!
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Old 02-01-2012, 08:17 AM   #4
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You said you replaced the Bargman due to the fault indication while towing.
Is there a chance it was wired incorrectly?
I am wondering if that is causing your brake controller issue.
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Old 02-01-2012, 09:04 AM   #5
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You might also try going to the Ford SuperDuty website and posting your question. I know the first year of the integrated brake controller (2005), they had some issues with them, but this is the first I've heard of anyone frying one (or potentially frying). Here's their link:

Super Duty & Heavy Duty - Ford Truck Enthusiasts Forums

Good luck.
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Old 02-01-2012, 03:18 PM   #6
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My Prodigy brake controller came with a warning that activating the
emergency brake switch while plugged in would fry the controller.

Hopefully you just blew a fuse somewhere.
No idea what was causing your hit and miss fault but pulling the emergency
brake cable while plugged in is a no-no.
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Old 02-01-2012, 03:37 PM   #7
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Quote:
Originally Posted by KyDan View Post
My Prodigy brake controller came with a warning that activating the emergency brake switch while plugged in would fry the controller.
Dan,
I don't remember reading a warning like that in manual of my GMC with integrated brake controller. If this is a problem then it darn well should have been there!

I am going out to the truck and check the manual again.
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Old 02-01-2012, 07:43 PM   #8
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No warning like that in the Fords either that I've ever seen or heard.
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Old 02-02-2012, 01:08 AM   #9
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Its kinda neat how threads develop. Pulling the breakaway advice is 50/50. I know I did and I don't know if it added or is the prob.
Today I checked all fuses, found good. Checked female 7 pin on TV, no power to blue brake #2. Removed harness to plug, no power, while brakes depressed ,running or not. Spent remainder of day visually searching for shorted blue wire. Gave up as don't have the “where-with-all” knowledge or tools to proceed.

Read on the FTE site several owners experiencing similar ( TFC at startup, intermittent, and while not connected ) and one the exact prob as mine. (nothing) The ones fixed were at the Ford dealer, mostly new controller, master cylinder, diodes, sensor or relay. Many were not resolved. I think tomorrow I'll look at the MC and firewall better. Sorry I'm not yet trusting about taking it to Ford, I have my reasons like most. BUT they do have the tech training and diagnostics for their own system. I can also get a Prodigy installed ??
Thanks for the replies.

I've owned Fords 30 years now. Did someone say Hemi ?Ņ!

2005 4x4 (never needed yet) SD FORD DIESEL...wish i had that '00 non egr, no cat, 2wd, Red Clifford sometimes.
BUT My '05 been good, makes JJ happy
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Old 02-02-2012, 09:03 AM   #10
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look for 40-amp circuit breaker on fire wall. May look like this. Blue wire should be attached.
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