Troubleshooting Warning Power Overload On Tekonsha Prodigy P3 Brake Controller

Updated 08/08/2017 | Published 08/06/2017

Question:

My son replaced my old receiver on my truck now my brake controller is flashing a power over load message. I can not access the on board diagnostics. I cant figure out where to look for the problem. Have checked power at the source, at the receiver plug in, and the trailer. Have any Ideas?

asked by: Sherri

Expert Reply:

Your Tekonsha Prodigy P3 Trailer Brake Controller # 90195 when flashing Warning! Overload No Brakes, is detecting an excessive current overload condition during operation according to the installation details I've attached. This means there is a short somewhere on the brake output circuit on either the truck or the trailer.

Start by examining the trailer connector. Make sure that the pins on the vehicle side of the connection and the sockets on the trailer side are not damaged, bent, or corroded. If you can see green corrosion on the pins or the sockets, there is a possibility that the corrosion may have spread to the interior of the connector itself, causing a short.

Then trace the output circuit back from the connector all the way to the trailer brake magnets. Check the brake output wire (usually a blue wire) for pinch points or worn or cracked insulation. If at any point in the circuit there is copper conductor wire showing, it can possibly short out on the trailer frame.

You will also want to examine your brake magnets and their connections. Make sure that the ground connection for each magnet is securely attached to the trailer frame. Check that the brake magnets are not excessively worn. If you pull the brake drum off and can see the copper windings through the face of the magnet, it is time to replace them. I've attached an article on how to test your magnets.

expert reply by: Jason S