New Fuzion with brake problems

[T-bones]

So on the way to our last camping trip I noticed my gas mileage going out the widow, before I would avg 19-22L/100km(sorry that's what we do up here in Canada) and 3/4 of the way my mileage went up to 30L/100km and my P3 controller started telling me I had no brakes and there was an "input overload". Now this would come and go every 2-10 min and stay on for 20-60sec, it was enough to pull over and reconnect the factory controller in the dodge just in case it was the P3. It wasn't the case, the dash would blink and tell me to check trailer wiring and no brakes.
When I got to location I found one of the lines to the rear axle was out enough that it rubbed on the rim and was possibly grounding on the brake drum, so I taped it up and figured problem solved right? NO
On the return trip same issue and same excessive fuel consumption as well, mind u I did have a full load and 2 Harley's in the back. So I get home unloaded everything and took it to the stealership for the check up. They also found 1 marrett connection in a junction box which the plastic cover had come off. Problem solved right....NO
Picked it up tonight after they had closed got it about 20 miles and the "no brakes" flashed in and then back out, so I pulled a 180 and back to drop it off again and on the rest of the way I quickly lost the brakes twice.
As I pulled into their parking lot one of the salesmen was unloading a boat so we had a chat and it turns out he actually went for the ride along when they tested it out. He said in the Ford they were pulling it quickly said trailer disconnected and they thought nothing of it! I mean really?...
So now I wait till tomorrow and see what happens.
I'm wondering if anyone else has heard of the brakes shorting and dragging slightly, because after unloading it on the way to the dealer and even the back and forth it still seams to be pulling like the brakes might be dragging?

[T-bones]

Here's another side note, I also had one of my tires on the front axle develop 2 bulges after the first trip(figured blown belts) I called and complained to keystone and they are shipping me a new tire. While it was at the shop I had them pull that tire and rim and replace it with the spare till the new tire arrives, now while the pulled it they checked the brakes and said they were fine on the front axel. But the bare wire I found were on the rear axel? Guess ill be calling back in tomorrow to have them check the rear if they haven't already today.

[BobWanderer]

2btowed wrote:
Get an infarad thermometer and shoot each hub where brakes are at.It tells you real quick if you have brake problem,hot if rubbing and cold if not working.I shoot each tire also and it tells if one is hotter than others,low pressure or seperation on the way.Quick and easy,at each stop.

That works for sure, I use it on most trips.
One time a tire was about 10* warmer than the others, we were close to camp so I went on.
Setting up camp the tire chock would not fit between the tires, the tire had started to separate.

to the O P
If in fact the brakes were dragging that long, they very well could be damaged, nothing but a complete tear down and through inspection would satisfy me. That includes the bearings.

[2btowed]

Get an infarad thermometer and shoot each hub where brakes are at.It tells you real quick if you have brake problem,hot if rubbing and cold if not working.I shoot each tire also and it tells if one is hotter than others,low pressure or seperation on the way.Quick and easy,at each stop.

[mapguy]

Input overload is a short to ground. Bad connection, chafed wire, magnet lead wire and or failed magnet are possible causes. They need to check voltage and current to each magnet. That will help isolate the problem. The people that worked on the trailer are real borderline in competence....

[T-bones]

That was step #1, they opened all junction boxes and thats where they found the bare marrett. I'm being told they have to go down the keystone check list one by one before they can drop the belly and check it out.

[ScottG]

Did you ever feel the wheels to see if the brakes were hot?
I honestly don't think the brakes were dragging. More likely there is a wiring problem. (Bad mileage is going to be normal)
Since the controller(s) indicated "No brakes" then the wiring would most likely be "open" as opposed to being shorted - in which the P3 would indicate "Overload". You probably have a bad connection someplace. I would open up the junction box at the end of the umbilical cord and check for loose connections.

[T-bones]

I'll have them check the breakaway as well? I suppose it could be the two issues at once, but I've never had the brakeaway trip on me before. When it's engaged is it just fully on or is there a point where it engages?

[carringb]

If the brakes were dragging, I would look at the breakaway switch. Worn/chaffed wires normally causes no-brakes and the P3 says short or overload. Even if the breakaway hasn't been tripped, doesn't mean its not bad. It may have held the brakes on, which could have burned out the magnets.