I have installed 2 different brake controllers in my 1995 dodge ramvan 2500. Each time when i apply brakes manually it will cause the controller to short out and smoke. what could i be doing wrong? I follow the manufactures wiring diagram.
Expert Reply:
It sounds like there is a direct short circuit somewhere in the system. Closely check all the wiring connections. The red wire on the controller should be connected to the cold side wire on the brake switch (the wire that shows voltage only when the brake is pressed.) I believe it is usually a white wire with a tan stripe. I would recommend using a circuit tester, like part # 40376, to verify this connection.
Closely examine the blue brake output wire that exits the rear of the controller, and runs to the trailer connecter, and ultimately, to the trailer brakes. Look for a broken wire or missing insulation that would allow the conductor to come into contact with the trailer or vehicle frame and short out. When you install the next controller, before you connect the trailer up, use the circuit tester to verify all your connections, and check that everything is working properly. Check the black wire at the rear of the controller for 12v, check the red brake wire as I described above, check that you are getting output on the blue wire when the over ride switch is activated on the brake controller.
expert reply by: Mike
