Brake Controller Only Outputs 3.4 Volts With Controller Set to Max  

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Expert Reply:

If you are testing the connector on your truck with the brake controller set to it highest setting and using the manual override then there is definitely a problem if you are only getting 3.4V.

You will want to start off by inspecting the connector on your truck. Look for any white or green looking residue as that can be corrosion. If that looks good then you will want to sever the Blue wire about 6 inches away from your brake controller and test it. If you are getting 12V at that point when using the manual override then you know that the brake controller wiring is the problem. You can either just run new wire or you can inspect your current wiring for any places where the wire is damaged, exposed, corroded, or even bent. Either way you will want to use 10 Gauge Wire # 10-1-1 and Butt Connectors # DW05745-5 to replace/rerun your wiring.

If you do not get 12V from the place where you severed the Blue wire then the problem is that your brake controller is shot and you will need a new one. If this is the case then I recommend going with the Tekonsha Prodigy P3 # 90195 as it is very easy to setup and use. If you have the connector under your driver's side dash on your 2006 Dodge Ram Pickup then you can use the Adapter # 3020-P as a plug-n-play option. Otherwise you will want to connect the wires from the pigtail as follows:

Blue - 7-Way on Truck
Red - Cold Side of Stop Light Switch
Black - 12V Power
White - Ground

Let me know if you use these troubleshooting steps and you are still experiencing problems and I can help you troubleshoot further.

expert reply by: Jon G

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