Trailer Brake Controller is Blowing Fuses on a 1994 Dodge Ram 1500

Question:

I hard wired a hopkins agility brake controller in my 1994 dodge ram 1500 and the fuseable link on the inline power keeps blowing the fuse. What would be my cause for this problem?

Expert Reply:

It sounds as if the controller is drawing too much power for the fuse or there is a short on the wiring that is causing the fuse to blow. When hardwiring in a brake controller, we recommend putting the brake controller power wire on a 20 or 30 amp self-resetting circuit breaker. Use # PK54520 for a 20 amp (good for 2 to 4 trailer brakes) or # PK54530 for a 30 amp (good for 6 to 8 trailer brakes).

The black wire is the 12 volt power wire and needs to be connected to the positive battery terminal via a 20 or 30 amp circuit breaker. The white wire needs to be attached to the negative battery terminal for ground. Red is input from the cold side of the brake switch. And blue is output to the trailer brakes.

I have included a link to an FAQ article that should help you.

If you have installed the controller correctly and there is no cut in the wiring touching bare metal there could be a short inside the brake controller itself. Sever the blue wire a few inches back from the controller and use a circuit tester like # 3808 to test the end coming from the brake controller. It should only show power when the manual override is applied. If it shows power all of the time then there is something wrong inside the controller and it will need to be replaced.

You will also want to make sure the vehicle and trailer side connectors are clean and free of corrosion.

expert reply by:
Michael H

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