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hazegray · 07-22-2013, 09:56 AM

We just picked up our 2004 KZ Frontier TT on Saturday from the dealer. Dang thing looks brand new I must say! Anyway, I noticed on the way back to my house, the trailer brakes were not working. I do have a brake controller and it previously worked on our popup. Anyway, I disconnected the TT from the truck and began troubleshooting. From the TT 7-pin connector, I jumped the power side to the brake input (fused protected) and no brake sounds from either of the four wheels. I then pulled the breakwaway plug from the switch and the switch got hot real fast. I put the plastic pin back in quickly as to not fry any wires. I had my son jump the pins again and backprobed the wires going into the wheel magnet, got power into the power wire, the other is ground. Again no sounds from the break magnet. I inspected all wiring, looking from chaffed/broken wires and found none. What the heck is going on?

jesilvas · 07-22-2013, 06:15 PM

I wouldn't go purely off sound.
Apply 12V directly to breaks like you've been doing, but drive forward. See if they lock up. If not, either your battery is bad or there is an issue with the breaks.

hazegray · 07-22-2013, 07:47 PM

Well I worked on it some more tonight. Seemed to be a broken wire in the main harness to the brakes. I jigged it and lost 12v and then got it back. Just have to drag new wires through and reconnect.

Swamp Man · 07-29-2013, 10:37 AM

HazyGray,

I would rewire all of the brakes with good #12 wire. The manufacturers run a very small guage wire through the axle tubes and so on. Also there are usual several splices in the wires between the A frame connection and the brakes. I had trouble for a couple of years, and finally rewire the works and no have all of the brakes I need. Use good crimp connectors that you heat shrink on and take your time.