OK all, maybe someone has some idea what's going on here. I've read through so many forum posts, I don't know what to think. Details:
1) Ford-150, 2x4, 5.4L, 3.73, factory towing package
2) 2012 Keystone Bullet Premier 31BHPR
3) Teskonsha Prodigy installed in 2005
Problem description: When hooking up the trailer and 7-pin line, everything works fine--trailer brakes normally. Driving for the first 10 miles or so and intermittently applying brakes--everything works fine. After that, things go downhill quickly. Over the next 5 miles, I get trailer braking only about 50% of the time with 'OL' (overload) appearing the other 50% of the time on the Prodigy. The problem gets progressively worse until >90% of the time 'OL' is displayed on the Prodigy when braking. Finally, when arriving home, and after coming to a dead stop, the brakes appear to work fine at slow, <5 mph, speeds. At a stop, the Prodigy displays brakes working normally. Will occasionally get an 'SH' (short) and even less occasionally an 'NC' (not connected) when applying the brakes, but very infrequently.
What I've checked:
1) F-150 connector, back and front for loose wires, corrosion, etc.
2) Trailer pigtail for corrosion, bent connectors.
3) Brake distribution bus for corrosion, loose connections, broken wires
4) Trailer emergency brake engagement for loose wires. Also engaged and reseated it several times with Prodigy disconnected
5) Wiring at trailer backing plates (outside the drum/backing plate)
6) Wiring coming through the axles of the trailer for chafing (have not removed the entire wires)
7) Prodigy connections to back of Prodigy unit, splices to instrument pigtail, and pigtail connection. Left Prodigy unplugged for 10+ minutes.
Everything I've checked so far has been negative for defects, and I've been unable to duplicate the problem with the wife in the truck and engaging the brakes (in the driveway) while I look for wiring problems--the brakes appear to work normally then!
Questions:
1) Does anyone think it's the Prodigy?
2) Why only while the trailer is in motion?
3) Any other thoughts for a nine month old trailer?
4) Anyone think Keystone will send someone to my house since the nearest dealer is 60+ miles away?
Camping World won't test the Prodigy only--they have to check out the entire tow vehicle to the tune of $57. They are the only Prodigy dealer close by.
Appreciate any thoughts.
Mike