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Old 02-15-2015, 06:28 PM   #1
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You may want to check your connector

As I was finishing off my SOLAR/Battery rewiring project, I opened the 4x4 electrical box on the frame under the front cap. I saw a bare wire sticking out of a connector with a rubber boot over it. I went to pull the boot closer for a better look and the blue wire came out of the connector. I removed the boot and the remaining 2 wires (from TT brakes) came out, but the connector was still in the boot. It looks like JAYCO used a pair of pliers to make the crimp, but they did not apply much pressure to crimp the connector (or tug on the wires to insure that the crimp was tight) . The wires just slid right out.

So, should I have needed the emergency braking provided by the TT's breakaway switch, I really do not think that the trailer brakes would have activated since there may have been only a couple strands (if any) supplying 12VDC to the brakes, or only one side of the TT's brakes.

I replaced it with a new crimped connector, and proper crimping tool. They are not going to come apart now.

To be safe, I would remove the cover off of your electrical box that contains the wiring for the BREAKAWAY switch and check your connectors. Better to be safe than sorry.

Don
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Old 02-15-2015, 06:55 PM   #2
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Thanks for the heads up. That's one of the few things I haven't checked on my TT. And I'm curious to find out just what's inside the box.
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Old 02-15-2015, 08:53 PM   #3
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And if you don't want a real shock, don't even look behind the electrical panel in the unit. Wire nuts and crimp connectors are only as good as the person that installs them.
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Old 02-16-2015, 02:12 PM   #4
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Extended the 4x4 electrical box

As I mentioned in the previous post, the brake connector was not really doing anything as it was not crimped properly, but also the box was bulging with wires. I also added a terminal post for GROUND and TT fused POSITIVE), which even made it more cramped. So I decided to make a trip to Lowes and get a 4x4 electrical box extender (see picture below). Now the wires are not jammed into the original 4x4. Yes I tagged everything for whomever gets the TT next.

Don
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Electrical box 4x4 extention.jpg  
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Old 02-16-2015, 02:18 PM   #5
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Quote:
Originally Posted by rryman View Post
And if you don't want a real shock, don't even look behind the electrical panel in the unit. Wire nuts and crimp connectors are only as good as the person that installs them.
That's one of the first things I did when I bought my TT. Made sure that every electrical connection back there was tight and secure. It wasn't in too bad of shape, actually.
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Old 02-16-2015, 02:20 PM   #6
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Quote:
Originally Posted by Mustang65 View Post
As I mentioned in the previous post, the brake connector was not really doing anything as it was not crimped properly, but also the box was bulging with wires. I also added a terminal post for GROUND and TT fused POSITIVE), which even made it more cramped. So I decided to make a trip to Lowes and get a 4x4 electrical box extender (see picture below). Not the wires are not jammed into the original 4x4. Yes I tagged everything for whomever gets the TT next.

Don
That box extender really makes a difference. Looks good!
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Old 02-16-2015, 02:22 PM   #7
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Quote:
Originally Posted by Mustang65 View Post
As I mentioned in the previous post, the brake connector was not really doing anything as it was not crimped properly, but also the box was bulging with wires. I also added a terminal post for GROUND and TT fused POSITIVE), which even made it more cramped. So I decided to make a trip to Lowes and get a 4x4 electrical box extender (see picture below). Not the wires are not jammed into the original 4x4. Yes I tagged everything for whomever gets the TT next.

Don
Don

Although I'm looking forward to getting my trailer and I appreciate this kind information and you giving us all a 'heads-up', I have to admit to a certain amount of dread when I start pulling things apart and looking under the pretty skin of my TT.
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Old 02-16-2015, 04:21 PM   #8
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Thanks Mustang 65 great information. I'm going to try the 4x4 extender,
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Old 02-18-2015, 07:02 AM   #9
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I have never been a fan of electrical crimps for automotive (or TT now) 12 volt wiring. I solder and heat shrink all 12 volt automotive connections. While crimps are convienient, they add resistance to a circuit, and the potential of water to get in and corrode at that connection.

I know a new project I'll aparently be doing one weekend (quickely now) to my TT....
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Old 02-27-2015, 08:23 AM   #10
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As far as I know crimping is preferred to soldering for any connection that vibration can affect. The soldered wire can flex and break down at the point where the solder ends. While crimps may have a bit more resistance they don't fatigue as easily as a soldered connection.

Cheers
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