Electric trailer brakes sticking

[RavensFan24]

Last night on my way home I noticed my trailer brakes were sticking. I'd let off the brake pedal, but the trailer brakes wouldn't release. If I came to a complete stop and pressed the brake pedal all the way down, it would release the trailer brake. Tapping the brake again did not release the electric brakes. It didn't happen every time I braked, but it was happening about 80% of the time. The brake controller is about 9 years old and is a Husky Journey HD (Part #52740 6108). The tow vehicle is a 2010 Tahoe and the trailer is a 2015 Keystone Premier. This is the first time this issue has showed up, but obviously it is something that has to be resolved ASAP to avoid any physical damage.

I looked up this issue online and found a few people saying to cut wires to test things, but I'd like to avoid this if at all possible. Anyone have any alternate suggestions for identifying and troubleshooting this issue? I'm guessing it's more of a controller issue than a trailer/brake issue, but figured I'd see what others thought before I spent too much time trying to find the cause.

[RavensFan24]

Turns out it was the brake light switch that was bad. Replaced it today for $10 and it appears all is working perfectly.

[Lynnmor]

RavensFan24 wrote:
After a lot of troubleshooting today, I'm thinking there is an issue with either the 7 pin connector or the computer system in the truck that is relaying the braking message to the controller.
.

The truck computer has nothing to do with your after-market controller.

[RavensFan24]

I've been talking with a friend that's an auto tech and he believes it's the brake switch. I'm ordering the OEM part online and it'll be here Monday. I believe this will fix the issue.

He had me test the adjustable pedals. They moved as they should, but then he said to reach behind the pedal and pull forward to see if that released the brakes and it did. As soon as I pulled forward on the pedal, the brake controller went from showing numbers on the screen as if it was applying brake power to saying 'no trailer connected'. This leads him to believe it's the brake switch. I'm sold for the $10 it'll cost me to fix it. I'll let you all know if that fixes the issue.

[SoundGuy]

RavensFan24 wrote:
I'm getting closer to finding the issue, but am still unsure what's causing it.

Open up the truck's 7-pin Bargman connector to see if there's a stray strand of wire that may be shorting one contact to another, which can happen if the wires aren't soldered but are secured in place with screws. You may also find that that 7-pin Bargman is actually a short adapter that converts to a round GM connector ... if so, just replacing that adapter may solve your problem.

[budwich]

as suggested, check you brake (pedal) switch.

NOTE: you have potentially a bigger problem than the "voltage" not releasing. First off, at "startup", with no trailer attached, the system (p3) should be indicating "NC" as in "NOT CONNECTED". It is "seeing" some form of "drain current" on the trailer brake side of the controller, indicating a "fictitious connection" to a trailer. Subsequently, it appear that the controller then is reading a brake signal from your brake pedal and applying "proportional voltage" for braking since limited / no deceleration is detected.

[RavensFan24]

It's an LT Z71 with HD trailering package. It had the Husky HD brake controller on it for almost 2 years with seemingly no issues. Replaced it due to this issue with the P3 brake controller, thinking that was the problem. After a lot of troubleshooting today, I'm thinking there is an issue with either the 7 pin connector or the computer system in the truck that is relaying the braking message to the controller.

Last night, The P3 was showing numbers on the screen as if it was braking with a trailer when the trailer was disconnected. Today, I couldn't recreate that issue, but the controller when connected to the trailer is still showing the braking, but not resetting back to 0.0 when I release the brake...unless I press ALL the way down on the brake and then release.

I also used a meter to test each pin in the 7 way plug. All work fine except the brake pin. When I Start the truck, it's at 0 volts. When I press the brake pedal the meter hovers around 1-1.5 volts. When I release the brake pedal, the meter stays at 1.5 volts. If I press the brake to the floor firmly and release the brake quickly, it resets back to 0.

I'm getting closer to finding the issue, but am still unsure what's causing it.

[Lynnmor]

RavensFan24 wrote:
Now the question is.....what's the issue with the truck?

Here is my list:

Bad brake light switch, (did you ever check the truck brake lights?)

Bad 7 way trailer connector

Bad controller

Bad wiring somewhere between controller and connector

[westend]

RavensFan24 wrote:
So I had a friend come over today with his truck and hook up to the trailer to test the brakes. It seems that the trailer brakes were engaging and releasing as they should. So now I know it's a truck issue and not a trailer issue. Now the question is.....what's the issue with the truck?

What truck, still the Tahoe? How is it equipped?

[RavensFan24]

So I had a friend come over today with his truck and hook up to the trailer to test the brakes. It seems that the trailer brakes were engaging and releasing as they should. So now I know it's a truck issue and not a trailer issue. Now the question is.....what's the issue with the truck?

[budwich]

the most recent "observations" (volts and no trailer connected) were without a trailer connected... so the problem isn't in the trailer as the OP has figured. First place to check would be the plug at the bumper (or equivalent) and also the brake switch on the brake pedal. Do you use the emergency brakes in the truck? Check that switch / contact also. It would appear that the P3 controller (where did that come from... you said initially you had a husky unit) is seeing a "brake apply" signal and then setting "low braking" ... maybe.... or if all else checks out (switches), then maybe the p3 isn't working correctly or maybe not wired correctly (check the splices / wiring pigtail).

[Wills6_4_Hemi]

eHoefler wrote:
Brake that are out of adjustment will hang up. When it happens, back up, if they release, you are way out of adjustment.

this has happened to mine. Once adjusted never another problem. They were to loose and binding up

[westend]

You may also have a short in the trailer umbilical or at the truck's connector. Shorting across from the power pin to the brake signal pin will exhibit the symptoms you describe. For purpose of elimination, you may also want to unpower your emergency brake switch for diagnosis, another possible cause of "constant on" brake function.

Good luck on this.

[RavensFan24]

I may be able to get someone else to test their truck with my trailer.

Something interesting i noticed tonight was that the P3 was showing numbers from 0.8- 1.8 on the controller that varied as i drove, without pressing the brake and without having a trailer attached. When i parked and was about to shut off the truck the P3 started flashing to tell me no trailer was connected.

A short somewhere in the truck seems more likely now that i saw that happen.

[opnspaces]

If you can hear the brakes buzzing when you are out of the vehicle and not touching the brakes then there is a short somewhere. the question now would be is the short in the truck or in the trailer.

Do you have a friend who tows that you can try their truck or trailer and see if the problem follows (stays with) the truck or the trailer?