I have been having some intermittant problems with my prodigy brakecontroller.

Symptoms are as follows:

The lights that activate when the engine is started usually glow continually. however

every now and then they flash and continue to flash until the motor is turned off.

Sometimes a P1 will appear when the brake pedal is depressed, not always though.

This may continue for several days and just when I am about to call in a Auto elec it all returns to normal.

This last time the lights began to flash and then turned into a single verticle bar and stayed that way for some time again.

In frustration turned every thing off and pulled out the phone to call for assistance and started the motor and everything was normal again.

I think I have eliminated the possibility of a broken wire or blown fuse. The controller was fitted by a reputable company.

It is around 6years old.

Has any one any clues as to what the problem may be,(apart from me,that is.), and what the solution could be.

Many Thanks

Kevin.

hako wrote:

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There is a common faults section on the Tekonsha website below that is pretty good, otherwise I guess you've checked that the brake switch/stoplight bulbs/plug at unit etc are OK. I've heard they usually replace the unit if it is the problem although 6 years might be stretching it. Good Luck.
http://www.tekonsha.com/content/support.aspx?path=faqs

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 Thanks for that Hako, I will check out that site and see if it helps.

Kevin

Not experienced with that particular unit but the earlier units had a problem where the controller was feeding power back to the brakelight switch which in turn would run a battery flat due to the stop lights being on, often when parked.

I have experienced this my self, just happened to see the stop lights come one while camping. Around the same time while travelling with the van in tow I felt the van brakes come on briefly a couple of times when there was a sharp dip in the road.

The auto lects had no explanation for this nor the manufacturer, the fix for this was to fit a one way diode to the activation curcuit from the brake light switch to the controler, this fixed my problem.

Maybe there is some thing similar with this one.

JC.

justcruisin01 wrote:

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Not experienced with that particular unit but the earlier units had a problem where the controller was feeding power back to the brakelight switch which in turn would run a battery flat due to the stop lights being on, often when parked.

I have experienced this my self, just happened to see the stop lights come one while camping. Around the same time while travelling with the van in tow I felt the van brakes come on briefly a couple of times when there was a sharp dip in the road.

The auto lects had no explanation for this nor the manufacturer, the fix for this was to fit a one way diode to the activation curcuit from the brake light switch to the controler, this fixed my problem.

Maybe there is some thing similar with this one.

JC,

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 Thanks JC, We were aware of the problem with the earlier models. The prodigy didn't have those problems.

This intermittant problem is a real headache, all is functioning correctly at present,

 Everything was working correctly when I hooked it up to the van before all this problem started.  Next time it goes haywire

I will connect the van on and see what happens.

kevin.    

I'm with jimricho on this.

I think what you have got is a problem return earth (i.e. cable not heavy enough)

PeterD wrote:

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patrolst wrote:

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I'm with jimricho on this.

I think what you have got is a problem return earth (i.e. cable not heavy enough)

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 The fix that JC described was for a problem with the Tekonsha Voyager controllers. It was a known problem within the controller circuit board. Some auto electricians did a quick and dirty (and illegal) fix by putting a diode in the wire to the brake light switch. This allowed the brake light circuit to trigger the controller. However it prevented the controller from illuminating the brake lights when you manually applied the van brakes as required by law.

Those who knew what they were doing had the Voyager replaced under warranty. The biggest problem was some of the unscrupulious ones were too lazy to go through the motions of warranty claims and get a replacement. Tekonsha acknowledged there was a problem in the controllers produced over  a couple of years. They willingly replaced them long after you would normally have expected warranty claims to expire.

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 By time mine acted up it would have been long out of warranty, there are possibily better ones out there now, maybe worth a look.

We have gone a bit off the original topic by now so while we are at this is there a unit that will apply full braking capacity via the manual control reguardless of the bias setting?

jimricho wrote:

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Check the instruction sheet as I think some vehicles require the installation of a relay somewhere in the circuit, not sure.

Also Tekonsha is most insistent that the earth wire from the unit is run right to the battery negative terminal. Some auto sparkies think they know better and don't do this, just picking up an earth somewhere in the wiring or connecting it to a convenient point on the body of the vehicle.

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 Jim, my earth wire goes direct to the battery as I fitted it myself.

JC.

PeterD wrote:

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JC, that business of adding the diode to the brake switch wire in your Voyager should not be done. When you operate the manual control lever on your controller it must illuminate your stop lights, the diode prevents this happening. Legally this renders your rig unroadworthy.

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 I dont find the need to operate it manualy, if the van is loaded correct , using WDBars & drive in a proper manner.

If & when you use the manual control you only get a moderate braking,( which is controled by your bias setting )to which I find is not enough to get the increased bias from the pendulem action within the controler.

There are many who don't even know the manual control is there.

patrolst wrote:

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I'm with jimricho on this.

I think what you have got is a problem return earth (i.e. cable not heavy enough)

---

 The fix that JC described was for a problem with the Tekonsha Voyager controllers. It was a known problem within the controller circuit board. Some auto electricians did a quick and dirty (and illegal) fix by putting a diode in the wire to the brake light switch. This allowed the brake light circuit to trigger the controller. However it prevented the controller from illuminating the brake lights when you manually applied the van brakes as required by law.

Those who knew what they were doing had the Voyager replaced under warranty. The biggest problem was some of the unscrupulious ones were too lazy to go through the motions of warranty claims and get a replacement. Tekonsha acknowledged there was a problem in the controllers produced over  a couple of years. They willingly replaced them long after you would normally have expected warranty claims to expire.

_wombat_ wrote:

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I bet you are driving a Toyota 80 Series, get a new replacement

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 G'Day Wombat, we've been a bit concerned at you not being on for a while. Welcome back!!

I used to drive a Toyota Camry V6 until it reached 300000Klms then presented it to No. 3 son

who is still using it without any problems. Now I am driving a x240 Great Wall 4wd which is giving me better mileage

than when towing than the Camry. I am seriously considering changing over to a new prodigy, when it all goes phutt

again (very technical term that.)I will borrow my mates new one and do a test.  Checked to see if an earth wire goes directly to the

 battery,doesn't seem to be there.

Thanks for all the great advice.

Kevin.

The original controller I had was the Tekonsha Voyager and had the problem that all worked except the override slide, once this was replaced all worked well (I couldn't claim it on warranty) it turned out to be a diode problem.

I installed a new Prodigy and rewired with a heavier cabling and proper earth, as the wiring that had been installed by the Auto Electrician was inadequate. (Also upgraded the wiring on the van also as there was too much voltage drop and the brakes did not feel as efficient as I would have liked.

Hence my comment re the: - earth wiring.

I made a couple of enquiries today reguarding a new controller,Check Repco & they had a Teconsha voyager for $ $130, normally $170 & commented that he didn't know how they could sell them for that discount. I asked about the Prodigy & said they can get them at $340.

I then checked a local auto tech, they had a Haymen Reece @ $130. Then advised me that Teconsha had been bought out by Haymen Reece, who are inturn owned by another company now but still trading as Haymen Reece. Hard to know who ownes what any more.

My guess would be that Repco is trying to move out a discontinued line, therefore the discount.

JC.

hako wrote:

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You can buy Tekonsha Prodigy P3's anytime on Ebay for $159 delivered to your door with full warranty. They even throw in a circuit breaker.
http://www.ebay.com.au/itm/TEKONSHA-P3-PRODIGY-CARAVAN-TRAILER-ELECTRIC-BRAKE-CONTROLLER-BONUS-/290822013620?pt=AU_Car_Parts_Accessories&hash=item43b657c2b4

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 Thanks, I was going to have a look at ebay . Seeing that Tekonsha has been bought out by Haymen Reece Makes me wonder if they are still producing units or is whats out there just a discontinued line.

More research to do yet.

JC.

The frustrating prodigy brake controller decided to stop working today.

Took it back to the installer and the tech guy checked everything out.

Checked the wiring and tested the prodigy itself.

Outcome ....nothing wrong with the prodigy, the wiring is ok and

is connected correctly.

Replaced the circuit breaker which appeared to be faulty.

Testing it this weekend on a short trip.

Many thanks for all your helpful suggestions, made me learn a lot more about

the electrical bits in the car.

Kevin 

justcruisin01 wrote:

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I then checked a local auto tech, they had a Haymen Reece @ $130. Then advised me that Teconsha had been bought out by Haymen Reece, who are inturn owned by another company now but still trading as Haymen Reece. Hard to know who ownes what any more.

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I missed this one earlier. JC you can inform your auto tech that Hayman Reese does not own Tekonsha (or vice versa.) The top of the food chain is the TriMas Corporation.  TriMas is organized into six reportable segments: Packaging, Energy, Aerospace & Defense, Engineered Components, Cequent Asia Pacific and Cequent Americas. If you look at this site you will see the companies owned by the Sequent Group.Tekonsha have been building brake controllers for HR for quite a few years.

As you said "Hard to know who ownes what any more." The bloke that gave the demo of the HR WDH weight demo at the Sydney show a couple of years ago handed out his card indicating he worked for Cequent.