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camperkilgore's avatar
Sep 24, 2015

Brake issues resolved....but.....

Wonderful info from forum members helped me solve an ongoing problem with my Prodigy P2 controller intermittently getting SH and OL errors.

I replaced the wires from the Pinbox connection to the brakes. I decided to use 12 gauge wire which is a step up from the wimpy wire that was original. I considered 10 gauge wire which has been used by some, but decided to use 12 gauge. Hope it's enough. I ensured that all connections were very good and I used waterproof boxes under the trailer to house most of the interconnections for the main brake line wires. Brakes work very well now.

My question now is:
Having increased the wire gauge of the trailer harness, I have now noticed that my 2003 Dodge Ram 2500 with tow package has much smaller wires from the controller (Prodigy P2) to the 7 pin connector at the back of the truck. Not sure of the gauge, but they look much smaller than 12 gauge. Looks like the blue wire which is the actual brake command should be larger.

Should I also increase the size of the blue wire from the 7 pin connector at the rear of the truck all the way to the controller? Would that improve braking even more? Anybody done that?
  • OK here is the finished wiring shots:

    J-Box with terminal strip...



    Left side brake wiring...



    Old system voltage (truck running) at right rear brake magnet (furthest from TV connector) was 12.9. With new wiring 13.4 enough difference to make it worth while in my opinion...
  • Coolerman wrote:
    OK here is the finished wiring shots:

    J-Box with terminal strip...



    Left side brake wiring...



    Old system voltage (truck running) at right rear brake magnet (furthest from TV connector) was 12.9. With new wiring 13.4 enough difference to make it worth while in my opinion...


    I did similar to yours with the junctions boxes. Used outdoor boxes with gaskets to seal up the boxes I didn't use terminal strips however. Wish I had. I just used wire nuts. I did use underground sprinkler wire nuts which are made for wet environments. They have a silicone(I think) stuff in the wire nuts which eliminates moisture.

    Still need to check voltages like you did. Brakes work very well though.

    I really like the way you looped the wires to allow for suspension movement. I may redo mine the same way. Seems like it would probably work better.

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