In 2012 I replaced all components of the electric brakes on the 5th wheel, from backing plate out and all bearing components (not hub). Last year (2015) I started getting "trailer wiring fault" intermittently then constantly on the last long trip home with complete trailer brake failure during these outages.Prior to winter, I replaced the easy stuff like the break away switch and the 7-way harness and all of their associated connectors. No luck.A couple of things I considered over the winter:1) Was running the brakes at a gain of 10 (max)2) If the gain is making the magnet pull harder against the hub to provide more force to the brakes, then it is probably causing more wear on the magnets, hub and the pads.Spent 8 hours this last weekend replacing magnets, repacking bearings and putting in new seals on all 4 wheels. Brake shoes still have another season or 2 left but I will need to replace (or refinish) the side of the hubs when I replace the pads.After the magnet replacement, no "trailer wiring faults" yet and the magnets did look pretty bad.I have reduced the gain to 7.5 but am not very happy with the stopping power from the trailer. Anyone else have similar observations or thoughts on this subject (yes I know, get disc brakes).

How are you adjusting the brakes?Consider a disc brake conversion.

A couple of things I considered over the winter: 1) Was running the brakes at a gain of 10 (max) 2) If the gain is making the magnet pull harder against the hub to provide more force to the brakes, then it is probably causing more wear on the magnets, hub and the pads.Perfectly normal and to be expected. The higher the gain, the higher the wear.I find it much cheaper to replace the entire brake assemblies rather than individual components. I purchase everything through: etrailer

Curious, what kind of truck and brake controller did you have previously.I don't know you, so I certainly can't say this applies to you, but just food for thought. I have often seen people who get their first integrated brake controller on their new truck, regardless of truck brand, are not happy with the brake performance. And it is not because the controller is not working well. Just the opposite. The new integrated controllers work so smoothly that you never feel the trailer dragging you back like the old plug-in controllers. It is unnerving, because that drag from the trailer kept us informed that the trailer brakes were working. So the urge is there to crank up the gain, when in fact the truck and trailer are stopping in unison very well.Results in premature brake wear. Also results in lots of false complaints to the dealers that something is wrong with the IBC.Probably not the case with you, but I'll just throw it out there.

WOW!! Gain set at 10. My 2010 Ram 3500 4x4 megacab towing 39' Keystone Alpine and my gain was 5.5 until I put EBC green pads on the TV and reset gain to 6.5 cuz the truck was stopping more and 5ver was "pushing".

i don't know about that gain. 6.5 is the magic number for the 2012 Ford.

Electric Trailer Brakes and Gain Caused Wear | Good Sam Community

handsome51
Explorer
Apr 26, 2016
Take a look at the wiring on the axles. I think you will notice how small the wires are that goes to the backing plate and from one side of the axle backing plate to the other one. I went a rewired the axles with #12 wire. Then I saudered the connection at the two wires at the backing plate before I put the twist nut on. Talk about a increase in breaking. I use to have to set mine when I was on the highway and then again in town. Now it is on one setting all the time. By using a bigger wire you are cutting down on the resistance and you increase the current flow to the magnets. This would be the next thing to look at.
While the factory axle wire runs through the axle from one side to the other . I bought a plastic tube used to house wires and mounted it on the outside of the axle tube. Tied it to the axle tube with cable ties.
Memphisdoug
Explorer
Apr 26, 2016
I think you need to look at the wires running through the axles from one side to another. It sounds like you might have worn through the insulation somewhere and are getting intermittent grounds inside the axles. I had to replace mine for this reason. I ran the wires on the back of the axles instead of inside.
Jerry_B
Explorer
Apr 28, 2016
I just replaced my 8k white wire magnets with 10k yellow ones. Braking performance has improved.
MPD56
Explorer
May 11, 2016
Just my 2 cents

The "trailer wiring fault" is just that. The controller knows that a trailer is connected and if it doesn't like the current it sees by monitoring it. Since you have tried it on 3 other Ford IBC controllers it might not be them. You can get this message on a ford without a trailer connected (I did on my 08)caused by road salt in the truck's trialer connector.

I have a 2013 F350 now and the IBC acts different then my 08 and different then a 2015. One reason is the transmission or engine braking. Also the IBC monitors foreward momentum so it is hard by seating in the dirver's seat if the controller is working. I have a brake controller tester/simulator.

My guess is your problem is caused by a electrical problem on the trailer and not a mechanical problem. Most likely a wire on the brake magnet circuit because that is what the controller monitors to give you that message.

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Electric Trailer Brakes and Gain Caused Wear

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