Trailer Brake Controller

2015xlt · Jan 3, 2022

I have searched as much as I can and have not found the same issue that I’m having. I will give as much info as I can:
2015 Expedition xlt with HD tow package.
I have towed multiple trailers with 4 pin and 7 pin and never had an issue. Trailer brakes work as desired.
I purchased a new trailer; with two axle brakes. First few times I towed no issue.
I towed again and it stated “trailer wiring fault” and no trailer brake engagement. All lights still working great.

I brought expy and trailer in the shop and checked all the connections. Found no issues. Went to leave my shop and brakes were locked up (fully engaged) unable to release brakes unless I unplugged 7 pin. As soon as I plugged back in they fully engaged. Tried messing with it for awhile until I noticed a lovely burning smell coming from the dash. Immediately unplugged 7 pin and ripped the ITBC out of the dash and unplugged it. It was very hot, obviously fried.

Took trailer back to dealer and had them go through the trailer and test of their machines and on multiple vehicles there with no issues.

I ordered a new ITBC module, installed and connected 7 pin. Again instantly fully engaged brakes and fried that ITBC.

Again trailer works fine on other vehicles. No shorts, no grounding issues. Without my ITBC installed lights work, no loose connections, good ground.

Any suggestions before I fry another ITBC?

Edit: should I keep trying with the OEM or just install and aftermarket?

When installing the aftermarket will the error codes stop displaying “trailer brake module error” or do I need to go in forscan and delete/remove the option?
Thanks!

99WhiteC5Coupe · Jan 3, 2022

2015xlt said:
I have searched as much as I can and have not found the same issue that I’m having. I will give as much info as I can:
2015 Expedition xlt with HD tow package.
I have towed multiple trailers with 4 pin and 7 pin and never had an issue. Trailer brakes work as desired.
I purchased a new trailer; with two axle brakes. First few times I towed no issue.
I towed again and it stated “trailer wiring fault” and no trailer brake engagement. All lights still working great.

I brought expy and trailer in the shop and checked all the connections. Found no issues. Went to leave my shop and brakes were locked up (fully engaged) unable to release brakes unless I unplugged 7 pin. As soon as I plugged back in they fully engaged. Tried messing with it for awhile until I noticed a lovely burning smell coming from the dash. Immediately unplugged 7 pin and ripped the ITBC out of the dash and unplugged it. It was very hot, obviously fried.

Took trailer back to dealer and had them go through the trailer and test of their machines and on multiple vehicles there with no issues.

I ordered a new ITBC module, installed and connected 7 pin. Again instantly fully engaged brakes and fried that ITBC.

Again trailer works fine on other vehicles. No shorts, no grounding issues. Without my ITBC installed lights work, no loose connections, good ground.

Any suggestions before I fry another ITBC?

Edit: should I keep trying with the OEM or just install and aftermarket?

When installing the aftermarket will the error codes stop displaying “trailer brake module error” or do I need to go in forscan and delete/remove the option?
Thanks!

Can’t help you - but have a similar problem.

I ordered and bought a new 2015 Ford Expedition Limited 4x4 with the HD trailer package (standard).

Since new, the vehicle has intermittently displayed the “trailer wiring fault” message. I have never towed or even connected a harness to the four or seven pin connector.

Repeated trips to the selling Ford dealer - and I was told there were no fault codes stored, thus no problem. I took pictures of messages - but the dealer said they were not helpful. The Ford dealer was incapable of trouble shooting an electrical defect.

Now, with 90,*** miles on the vehicle - it continues to randomly and intermittently display that message (and since new, it also displays the “No Key Detected” message randomly and intermittently).

I know this doesen’t help you - but if you determine what is causing the “trailer wiring fault” message - please post the solution. Thank you.

Hamfisted · Jan 3, 2022

Most people with the issue have determined Ford's brake controller is total crap and went with an aftermarket controller. If you unplug the Ford controller the problem goes away right ?

2015xlt · Jan 4, 2022

Hamfisted said:
Most people with the issue have determined Ford's brake controller is total crap and went with an aftermarket controller. If you unplug the Ford controller the problem goes away right ?

Unfortunately no. When the stock one is unplugged dash says trailer brake module malfunction and beeps obnoxiously as usual. I’m fine with aftermarket as long as the dang light and beeping goes away.

99WhiteC5Coupe · Jan 4, 2022

2015xlt said:
Unfortunately no. When the stock one is unplugged dash says trailer brake module malfunction and beeps obnoxiously as usual. I’m fine with aftermarket as long as the dang light and beeping goes away.

In a previous post (I wished I had bookmarked it...) a poster said he found the cause of several DIC warning messages on the 2015 - 2017 Expedtion models.

The poster said he removed the plastic tray in the third row (on the top of the left or driver side) and found a large plastic, multi-wire connector there. It was not fully snapped together, and when he fully seated the connectors - the warning messages stopped.

2015xlt · Jan 4, 2022

99WhiteC5Coupe said:
In a previous post (I wished I had bookmarked it...) a poster said he found the cause of several DIC warning messages on the 2015 - 2017 Expedtion models.

The poster said he removed the plastic tray in the third row (on the top of the left or driver side) and found a large plastic, multi-wire connector there. It was not fully snapped together, and when he fully seated the connectors - the warning messages stopped.

Ok, yes I read that post yesterday. I will certainly go and try that.

GeorgeH · Jan 8, 2022

2015xlt said:
I have searched as much as I can and have not found the same issue that I’m having. I will give as much info as I can:
2015 Expedition xlt with HD tow package.
I have towed multiple trailers with 4 pin and 7 pin and never had an issue. Trailer brakes work as desired.
I purchased a new trailer; with two axle brakes. First few times I towed no issue.
I towed again and it stated “trailer wiring fault” and no trailer brake engagement. All lights still working great.

I brought expy and trailer in the shop and checked all the connections. Found no issues. Went to leave my shop and brakes were locked up (fully engaged) unable to release brakes unless I unplugged 7 pin. As soon as I plugged back in they fully engaged. Tried messing with it for awhile until I noticed a lovely burning smell coming from the dash. Immediately unplugged 7 pin and ripped the ITBC out of the dash and unplugged it. It was very hot, obviously fried.

Took trailer back to dealer and had them go through the trailer and test of their machines and on multiple vehicles there with no issues.

I ordered a new ITBC module, installed and connected 7 pin. Again instantly fully engaged brakes and fried that ITBC.

Again trailer works fine on other vehicles. No shorts, no grounding issues. Without my ITBC installed lights work, no loose connections, good ground.

Any suggestions before I fry another ITBC?

Edit: should I keep trying with the OEM or just install and aftermarket?

When installing the aftermarket will the error codes stop displaying “trailer brake module error” or do I need to go in forscan and delete/remove the option?
Thanks!

I think one important point is "the trailer works fine on other vehicles". So the problem is in the brake controller or wiring harness. So I would solve this problem with a new Tekonsha P3 brake controller and all new wiring including a new 7 pin plug. I would bypass all of the Ford original wiring. You might need to delete/remove" the OEM brake control option. But I would try to bypass the Ford system first and see it that solves the problem.

timo482 · Jan 8, 2022

The real problem is that the ford controller works with the stability control system. So in a bad situation it’s better. Something is wrong in the wiring, Just ignoring it will kick the can. If smoke has already escaped twice there is a fire risk that will not leave by ignoring it

mygsris2slo4u · Jan 8, 2022

If you fried two brake controllers it leads me to think that it's the actual trailer module and not just the brake controller. I know I saw this issue posted previously at some point, but cannot find the thread.

2015xlt · Jan 8, 2022

Thank you for all the info!!!! I’ll starting trying and researching the things mentioned above!

Trailer Brake Controller

2015xlt

New Member

99WhiteC5Coupe

Full Access Members

Hamfisted

Full Access Members

2015xlt

New Member

99WhiteC5Coupe

Full Access Members

2015xlt

New Member

GeorgeH

New Member

timo482

Active Member

mygsris2slo4u

Member

2015xlt

New Member

Similar threads

Latest posts

Members online

Forum statistics

Share this page