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Old 05-06-2016, 03:03 PM   #1
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First trip cancelled: Brake overload condition

With the rain we've been getting, I delayed testing the trailer until just about time to go. Well I hooked up and the P3 showed a Brake Short (no brakes) then after I moved the trailer the indicator turned green.

Moving another foot and I get brake overload. I checked all the visible wires and connections and everything is fine. Since I have a 7-way in the bed and bumper, I tried both with the same error.

I am not going to chance it, so cancelled our weekend camping plan, hopefully it'll stop raining and I'll start to diagnose what is happening. I suspect a magnet, so going to start from the wheels forward.

Anyone have this and find the problem?
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Old 05-06-2016, 05:09 PM   #2
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I wonder if one of the brake magnets is worn down to the coils, and shorting out to the brake drum sporadically as it rotates?
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Old 05-06-2016, 05:20 PM   #3
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Originally Posted by nylyon View Post
With the rain we've been getting, I delayed testing the trailer until just about time to go. Well I hooked up and the P3 showed a Brake Short (no brakes) then after I moved the trailer the indicator turned green.

Moving another foot and I get brake overload. I checked all the visible wires and connections and everything is fine. Since I have a 7-way in the bed and bumper, I tried both with the same error.

I am not going to chance it, so cancelled our weekend camping plan, hopefully it'll stop raining and I'll start to diagnose what is happening. I suspect a magnet, so going to start from the wheels forward.

Anyone have this and find the problem?
Go back in your junction box where all the wires come together. Take off the wire nuts and retighten them. Had a neighbor who was headed out on his first trip with the same issue. Turned outed to being poor connections in that junction box.
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Old 05-06-2016, 05:35 PM   #4
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Going to test both of these. I'll jack up each wheel and spin see if the problem occurs, and I'll check where the wires splice I at the hitch.
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Old 05-15-2016, 10:54 AM   #5
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I finally got to looking into this issue. I started by checking each wheel by driving one wheel up onto a 6x6, then using a bottle jack on the other wheel on the same side to raise it enough to spin the wheel. I did this on each wheel, and on the last wheel I was able to reproduce the issue.

I removed the wheel and what did I see?

I cut the wire, butt connected it, then shrink wrapped the connection and put it all back together. It looks like the clips on the wire were NEVER secured to the brake arm causing it to rub.

Looking forward to Memorial Day at Lake George now!
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Old 05-15-2016, 11:25 AM   #6
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I think I will be taking rubber hoses in sizes of 3/4", 5/8", 1/2", & 3/8" and completely go through my new TH's wiring and anywhere wiring touches areas such as ledges, frame, holes, brackets, paneling, etc., I will then cut the appropriate size hose to length and also slit the hose lengthwise followed by slipping hose over wire(s) and then tie strap together. This will 100% prevent the possibility of a rub through on wires at that point. I will also be doing this process behind the walls, inside cabinets and behind the electrical panel of which I can access. Yea, such may be a bit overboard but, my many years of VW TDI diesel background taught me that wiring strain relief and wire chaff prevention will be well worth it in the long run because eventually the shake, rattle and roll of the highway will most likely result in issues. The great thing about such a regiment is the fact it is a very inexpensive preventative measure.
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Old 05-15-2016, 12:04 PM   #7
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Well one suggestion with the tubing over wires is keep the slit positioned facing down so water doesn't accumulate inside and deteriorate the wiring insulation. I had a boat trailer one time that he did that around brake lines and they all rusted
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Old 05-15-2016, 12:48 PM   #8
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Well one suggestion with the tubing over wires is keep the slit positioned facing down so water doesn't accumulate inside and deteriorate the wiring insulation. I had a boat trailer one time that he did that around brake lines and they all rusted
Very good point! This is where silicone would be your friend however, I think that would be going overboard and your idea of slit down is awesome.
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Old 05-15-2016, 03:52 PM   #9
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This issue was inside the brake drum, the external wiring is just fine
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