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Troubleshooting Hayes Syncronizer Trailer Brake Controller


After having this brake installed and driven from the lot to our home, we noticed a hotinch burning smell, not quite electrical or plastic in nature. Is this normal? Is there a breaking in period? Also notable, this is the second unit we purchased and installed by the same service department at the dealer we bought our T@G trailer. We noticed the smell with the first unit as well and on our second trip out with the trailer, the unit stopped working. Our dealer said it was the unit itself and replaced it, but I suspect there might be a connection between the symptom and and the result. Any thoughts?


Helpful Expert Reply:

That is not normal. The Hayes Syncronizer Trailer Brake Controller - 1 to 2 Axles - Time Delayed # HA81725 should not give off any smell and should not be activating the brakes enough to cause smell if installed and adjusted properly. I've attached a video of this installation for you to reference.

When installed correctly, this unit should be adjusted for sensivity. This conroller has a red LED indicator on front of unit that illuminates when trailer's brakes are applied. This light glows brighter as power output increases. If it is not functioning like that, it is not working properly. If it is constantly lit, there is a good chance they put the red brake switch wire on the hot side of the switch instead of the cold side of the switch in which case your trailer brakes would be constantly engaged.

The other possibility is that the brakes on your trailer need adjusted and are engaged all the time, but you would know that without the brake controller being connected. It wouldn't be a new symptom.

I've attached some articles to further help.

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