Troubleshooting Hopkins Agility Brake Controller
Updated 08/02/2013 | Published 08/01/2013
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Question:
When I wired the brake controller the trailer connection light is on all the time. even with the truck off and trailer disconnected. When I hit the brakes nothing happens but when I hit the red button the short circuit comes up. Thanks for all your help.
asked by: Bobby L
Expert Reply:
What you are describing does indeed sound like a short circuit somewhere in the brake output circuit between the brake controller and the trailer connector at the rear bumper. You can confirm this by severing the blue wire a few inches behind where it exits the brake controller. If the problem goes away, you have confirmed the short. The first place to look for the short would be the trailer connector. Closely examine the connector for damage or corrosion. If you can find white or green corrosion on the pins of the connector, the corrosion might have spread to the interior of the connector to where the wires connect to the terminals. Clean or replace the connector as needed.
If the connector checks out okay, the problem lies in the wiring between the connector and the controller. Cut the wire feeding the # 2 terminal on the trailer connector. Use a butt connector like part # 05732-2 to attach a length of 10 gauge wire, like part # 10-1-1 long enough to pass under the vehicle, into the engine compartment and through the firewall to the brake controller. Join this wire to the blue wire you cut earlier, thus abandoning the existing brake output circuit.
I have linked you to a Brake Controller Troubleshooting FAQ article that you might find helpful.
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