Why is my Brake Controller Reading Overload and How Can I Find Where the Problem is?

Expert Reply:

If your controller, item # 5500, is reading overload without the trailer connected then that means there is a short in the blue trailer feed wire on the vehicle.

If the controller is reading overload only when the trailer is connected then there is a short or overload in the trailer wiring or breaks.

Use a circuit tester, item # 3808 if you need one, to test the wiring to find out where the short is. If it is on the trailer end and you cannot find a wiring problem then the problem may be that the brake magnets are worn out and they will need to be replaced. If you can see the copper windings in the magnets then they are in need of replacement. We have replacement magnets available (see link).

expert reply by: Bob G