Tracking Down and Repairing OL Error Code on Draw-Tite # 5500 Brake Controller on 2005 Chevy Van

Question:

hay guys i have a 05 chv van 2500 with a draw tight controler that workd well on other trl but o hook up to one. i get ol the controll checks good but when i hook an other truck to it with the same controler ther is no problem. i have installed all new mags and wiring looks good.

asked by: Jim

Expert Reply:

The OL error code indicates that there is a problem somewhere in the brake controller output circuit, between the controller itself and the trailer brakes.

Since you have used the controller in another vehicle with the same controller without problems, the only possibility remaining is a problem in the wiring of the van.

The most likely culprit is the trailer connector on the van. Check the connector to ensure that it is not damaged. Closely examine the contact pins in the trailer connector socket. If you see any green or white corrosion on the pins, there is a good chance that some of that corrosion has spread to the interior of the connector, and maybe even to the terminals where the wiring attaches to the connector. Closely examine the connector for corrosion, and clean or replace if necessary. While a helper activates the manual switch on the controller, use a circuit tester like # 40376 or a multimeter like # BTMT15 on the pin in the 5:00 position on the connector. You should show current with the manual switch activated. If you are not seeing current, test the wire at the rear of the connector that feeds the pin. If you do not read power there, you will then test the blue wire exiting the rear of the controller for power while the manual switch is activated. If you have power leaving the controller, but it is not reaching the connector or the pin, you will need a length of 10 gauge wire, part # 10-1-1 to run a new output circuit from the controller to the trailer connector.

expert reply by: Mike L