Brakes Will Not Release and Brake Lights Stay On Using Manual Override On Hayes G2 Brake Boss

Question:

Hayes G2 Brake Boss Trailer Brake Controller # HA81792BB 19 ft single axle trailer towed with 1996 Dodge Ram 4x4. Has been working geat for 2 years. When i manually engage the brakes at slow speed to check operation. The controller keeps the brakes on at 15 and will not release. Also the brake lights stay on. Once I unplug it brake lights go off. If i let it sit then plug it back in it works normal until the manual lever is pulled again. I have disassembled the truck connector and cleaned all the contacts. Any idea ? Will it have to be replaced?

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Expert Reply:

If the manual override is not releasing then I am afraid there is an internal error on the Hayes G2 Brake Boss Trailer Brake Controller part # HA81792BB and it will need to be replaced as brake controllers are not repairable. The brake lights are staying on because the brake controller sends a signal to these lights with the manual override applied.

For replacement, I recommend upgrading to the Hayes Genesis Trailer Brake Controller part # HA81790 which will use the same plug as your Hayes G2 Brake Boss for a plug and play install. The Genesis when compared to the Brake Boss has more boost settings which equates to more stopping power as well as a larger display. The manual override is also easier to reach and a bit less error prone. The Genesis come with a lifetime warranty so it will be the last brake controller you ever have to buy.

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Conner L

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