Tekonsha - brakes overloaded message

[The motor guy]

My trailer brake controller occassionally Says brakes overloaded, no brakes. What does this mean? They still work too. One time I drove off and forgot to plug in the connector and knew as soon as I got to the first stop sign.

 

[Ursatdx]

From AI:

If your brake controller intermittently indicates "brakes overloaded" even though the brakes seem to be working, the most likely culprit is a loose or faulty connection within the trailer brake wiring, particularly at the brake magnets, which could be causing a temporary short circuit or intermittent resistance when the brakes are applied, triggering the overload signal on the controller.

 

[mk378]

That means there is a short in the wiring from the blue wire to ground. Also check the resistance of the brake magnet coils. If you can't find any shorts on the trailer itself, pull the brake drums to inspect the magnets and the wiring inside the drum.

 

[The motor guy]

Could they just be out of adjustment?

 

[The motor guy]

It's not doing it today now. It's a proportional controller. Harder you hit the brakes, the more they apply back there.

 

[supton]

It's not doing it today now. It's a proportional controller. Harder you hit the brakes, the more they apply back there.

Sounds like an intermittent wiring problem. Look for a chafed wire, could be anywhere, but it's unlikely to be in split loom tubing, not unless if something got in there and chewed away at it. look at both tow vehicle and trailer, any place where the wire can rub against the frame.

 

[The motor guy]

Sounds like an intermittent wiring problem. Look for a chafed wire, could be anywhere, but it's unlikely to be in split loom tubing, not unless if something got in there and chewed away at it. look at both tow vehicle and trailer, any place where the wire can rub against the frame.

If I rememebr right the only exposed wiring is down by the drums. The rest looks like an extension cord. It's a really nice setup. Maybe I need to go under there and make a fresh splice with new butt connectors.

 

[mk378]

Could they just be out of adjustment?

No. The controller is only looking at electrical performance. It's an electrical issue.

 

[The motor guy]

No. The controller is only looking at electrical performance. It's an electrical issue.

Well I mean it did the same thing with my other truck that doesn't have 4 wheel disc brakes with dual piston calipers. This newer dodge the trailer brakes really aren't needed. Worked fine on the 3rd gen dodge and the red overload warning on the old 2nd gen. I'll crawl under there and give them a looksie though.

 

[meep]

Brake circuit can handle a few amps. For it to show that message suggests it’s not shorting to a light circuit but to ground somewhere, even in the plug.