Originally Posted by s1000pre
Two dealers now have told me there is nothing they can do. It must be my trailer. This is the same exact response I got from two dealers last year with my F150.
I hate say it but I think it is time you look harder at the trailer. First off, your gain setting is way too high in my opinion. I have had 2015 F150, 2018 F150, and now 2022 F250 and never needed gain more than 5 on any of them. I have had no issues with the brake controller on any of them and I did have the recall on my latest. Some ideas on things check:
1). Is the Bargman connector seating properly and fully into the TV 7-way. The connector that came with our 2017 25FB would not plug in fully due to molding issues which require a new trailer side connector to fix. Also check pin splay and maybe try some dielectric grease.
2) Maybe you have a ground issue. Any loose connection in the ground line would result in the return path going through the hitch which could cause erratic behavior. I would check ground line from connector to junction box in the trailer and to frame ground.
3) Check the break away switch. Not sure what to look for, but...
4) You may want to take the Airstream into a dealer and have them check the Dexter axle brakes. We had a pre-mature failure on one and it turned out Dexter had some brake issues and they covered replacement including labor under warranty.
I am sure this is a very frustrating problem but it would be a shame to put in an aftermarket controller and find out you still have the same issues.