When Accelerating the Hokins InSIGHT Brake Controller Applies the Trailer Brakes

Published 12/18/2014

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Question:

I have an Insight Flex controller. It works as it should when applying the brakes, numbers as high as 45, however when I accelerate I see the controller showing an increase on the readout... 5/ 10/ 20/ 25/ and even have seen it get as high as 30. Question is, is the brakes actually being applied even though Im not applying the brakes? Triple checked wiring: Module pack is pointed with wiring to the front of vehicle: Module pack is perfectly level north/south and east/west: Been speaking with Hopkins and they say they have never seen this before. Vehicle: 2008 Chevy Tahoe LTZ Trailer: 2015 Tango 25RKS

asked by: Mark B

Expert Reply:

This is the first time I have heard of this issue with the Hopkins InSIGHT brake controller. It sounds like one of two things. First, it is possible that the brake controller red wire is not attached to the correct wire on your 2008 Chevy Tahoe. It should be attached to the Tahoe Light Blue with white stripe.

If that is correct might have a short somewhere. There are ways to test the controller to see if it is the problem. In the Tahoe cab you will need to sever the blue wire several inches from the back of the controller. Then use a circuit tester such as # PTW2993 to test the end of the blue wire coming out of the controller. It should only have power when you apply the manual override. If it shows power at any other time then there is something wrong with the controller and it will need to be replaced.

If it tests fine then reconnect the blue wire. Then move on to the truck side trailer connector. Many times, dirt or corrosion can cause a short in a trailer connector. Make sure the truck and the trailer side connectors are clean and free of corrosion inside and out.

You can test the brake output pin and it should only show power with the manual override. If it shows power any other time then there is a short somewhere between the connector and the brake controller you will need to track down.

If the truck side checks out fine then it could be the wiring to the brake magnets or the magnets themselves. Inspect the power wires to the magnets and look for pinched, frayed, or damaged wires and fix as needed. Make sure the ground wires are attached to clean and corrosion free bare metal surfaces.

You can visually inspect the magnets and if you can see the copper windings coming through the magnets will need to be replaced. To further test the magnets you can follow the help article I have linked. I have also included some help articles on testing and troubleshooting brake controllers for you.

expert reply by: Michael H