Braking Issues, I need help.

[TeamCyBo]

Hello all, i have started having brake pedal issues the last couple of times we have gone camping. First, I have a 2007 Expedition with heavy duty towing package. Our camper is a 2012 Sunnybrook 292RL. Here is what's happening. While driving through N. Ga. mountains towing our camper, I started having a problem with my brake pedal making noise and vibrating uncontrollably while braking. The situation only happens while going downhill and going into turns. My speed was about 25-35 mph. While driving and braking on a somewhat level road I had no instances at all no matter what speed or turns. This also only has occured while towing the camper so there is no problems with rotor pulsation on the Expy without the camper. When the vibration happens, I took note that there is no jerking or drag of the vehicle. I'm leaning towards some type of electrical problem. Maybe the brake controller is partly the cause. BTW, I'm an old automotive service manager and have seen most everything out there. This is unlike anything I have ever experienced. Any help on this would be greatly appreciated.

Thanks

[mchero]

Thanks for the post Bo! Glad its been resolved!

[TeamCyBo]

Thanks, I'm going to check on the warranty tomorrow. While I have had it only about a year, we have only used it maybe 8 times. We will see.

Bo

[time2roll]

Great to hear you have a resolution. I wonder if they will warranty it.

[TeamCyBo]

Ok, folks here is an update. I took the spare controller that is identical to the one in the Expy. I hooked up and drove until I found the right type of incline and proceeded to brake. Sure enough the pedal fluttering happens. I go through the the turn and pull off. I disconnected the controller and circled back to do the hill again. This time was smooth with no pedal flutter. I again pulled off and switched the controllers and connected it up. I then circled back a third time and with everything identical, settings and all went down the incline again and again, it was smooth with no pedal flutter. I drove to a couple of other spots and still all is good. I concluded that it must be a defective controller.

BTW, randall, thanks for the input. I already checked that TSB out, being an ex service manager and all. That TSB, according to my Ford dealer is in most part about the Traction and ABS dash lights flashing or staying on for no apparent reason.

I hope my experience may help someone else with a similar problem. Thanks for all of the suggestions and help.

Happy Trails to you all.
Bo

[riggsp]

Still sounds like the ABS system to me...typical action of ABS brakes when one or more wheels are trying to skid from overbraking...does the ABS light come on when this is happening?

[Harvard]

TeamCyBo wrote:
I thought of that but it only happens when towing. I also tried somthing. I put it in low gear to slow down and it actually happened without even touching the brake pedal.

From experience, what if...what if the rear mount on the transmission were free to move laterally and allow the front universal knuckle to rap against the exhaust or something like that....

[randallb]

You would think an ex service manager would know where to look. It took me 2 minutes to find your answer. TSB 08-14-02.
Randy

[TOOBOLD]

We had a problem like this in our 04 F150 and Ford actually replaced the entire brake assembly on the front end of the truck. There might be a TSB on this issue. I don't remember all the details as it happened in 2007, but I do remember that shaking when the brakes were applied.

[j-d]

Understood, however I remain suspicious. My logic is that towing causes the brakes to run just a little hotter, aggravating an issue that doesn't surface till the brakes are abnormally hot.
If you suspect ABS or another electrical/electronic problem, can you disconnect your trailer brakes (pull fuse or circuit breaker to the controller) and still drive safely enough to see if the problem goes away?
A weak ground can scare up all kinds of demons. Is all the wiring clean and tight?
***Please*** let us know what it turns out to be.

[TeamCyBo]

J-d,

Thanks for the response. As I said before, I'm an old automotive man and have done my share of brakes. This really feels nothing like a sticking caliper and it "only" occurs when towing. And the only time I have experienced it is when the vehicle is pointed downhill and in a curve. I know, go figure. This is really weird. The brakes have been checked out and calipers, all 4, move freely and the wear pattern on the pads is even on all 4 wheels.

Thanks

[j-d]

I read all the symptoms and replies so far.

Still, after reading so much that makes sense, I still suspect a...

...sticking brake caliper...

[TeamCyBo]

Spike,

Unfortunately, I don't have access to another trailer nor a tow vehicle. I would think it's relatively safe to disconnect the controller and tow the vehicle as long as I know the route. I may try to do that tomorrow. I don't get any signs of surge or bucking from the trailer nor the vehicle. It's just the pedal jumps and vibrates along with the noise like a solenoid kicking in and out.

Thanks

[spike99]

Only happens when towing????

Suggest connecting Trailer to a different Tow Vehicle and try to duplicate the problem. And, connect your Tow Vehicle to a different trailer. Does problem follow the Trailer? Does the problem follow the Tow Vehicle?

If cannot find a different trailer (with electric brakes) to test with, disconnect the Brake Controller and do another test drive. Does problem still exist? If yes, then its mechanical. If NO, then its electrical (mostly likely the brake controller).

Hope this helps.

[TeamCyBo]

Matt,
It's a Tekonsha Primus about a year old. It is very secure and mounted on the left side bottom of the dash near the e-brake. Probably about 20 deg. angle. The wiring seems to also be secure.

Thanks