6.7L Cummins Forum

I have a new 2010 2500 Mega cab with the integrated trailer brake controller. I find that any trailer I pull that the controller doesn't seem to put enough voltage to the trailer brakes. Trailer brakes are good and set properly, when you pull the break-away all 4 tires lock up. But when pulling under normal conditions the trailer wants to push the truck, regardless of setting 1 or 10. Any body else having troubles? I've had it in to two dealers and there answer is that it lights up a test light and therefore must be working.

Yes, i am having the exact same trouble, i have a 2011 2500 and mine does the same thing, i feel like i am pushing the brake pedal a lot harder than i need to be.

Perhaps you are dealing with a voltage loss in the trailer's braking system. In addition to using cheap electric brakes, the wiring is often undersized resulting it voltage loss. Or you might have some grounding issues and sub-standard wire connectors.

I suggest you trace down the brake wires, ground connections and wire connections.

There have been reports of the brake wire being routed through the tubular axle from one side to the other. The wire isn't secured and rubs to the point where the insulation is compromised causing voltage loss to the metal of the axle.

And upgrade to a direct wire from the A-frame to each brake. Use a stranded conductor rather than solid core wire. Also use the next size larger wire 12awg vs 14awg. Encase the wire in a plastic conduit that is securely zip-tied to frame to prevent snagging of flexing. Make a good clean connection at the brakes using a premium connector and insulate it if possible. This modification assures maximum voltage to the brakes, protects the wire from damage and gives you a better brake system.