2022 FORD F-350 SD Service Brakes Problems

Integrated trailer brake controller failing. Surging and randomly releasing trailer brakes. I tow a 16k lb. Trailer.

The contact owns a 2022 Ford F-350 SD. The contact stated that while hauling a trailer, the brakes failed to operate as needed. The vehicle was taken to the local dealer, who updated and replaced the Auxiliary Power Interface Module (APIM) several times. The vehicle was repaired, but the failure recurred. Additionally, the radio turned on without driver interaction. The contact stated that the Forward Collision Avoidance system and the mirrors were turning on and off, the crash alert was engaged, and the brake was applied without driver input. The steering wheel was vibrating. The manufacturer was contacted and declined a buyback of the vehicle. The failure mileage was approximately 100.

Mileage: 100

Trailer brakes continuously go out on multiple trailers with an associated right turn lamp fault. There was a related recall but did not cover all of the vehicles this is happening to. Manufacturer Recall Number: 22S17 NHTSA Recall Number: 22v193

Trailer brakes going on sporadically. Known problem…right turn lamp fault as well. [XXX] INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

Trailer brake control module shorts out intermittently causing trailer brakes to not work. This causes the vehicle and trailer to not be able to stop on time in a short distance. Dealer has confirmed that this is the issue. Error message is “trailer wiring fault” and “trailer disconnected” while driving with trailer attached.

The vehicle has a Gross Combined Weight Rating (GCWR) of 30,000 LBS. While towing, the vehicle would show on the dash at intermittent times "Trailer not connected." When this occurs, the trailer brakes are no longer operating placing all braking on the tow vehicle with the potential for brake fade or complete brake failure and catastrophic loss. This intermittent failure of the electrical brake system does not occur on other tow vehicles that were equipped with after-market brake controllers, such as Tekonsha. The vehicle was brought into the Ford Dealership to look into the issue. Ford had the truck for nearly two weeks and could not figure out the problem. After much self-research, it was determined that the factory installed brake controller cannot discriminate between trailers using electric brakes and trailers using electric/hydraulic brakes. The fix is to install an actuator (ETrailer Code DX35FR - Adapter Module for BrakeRite Electric Over Hydraulic Actuator - OE Ford, GM Brake Controllers) on the trailer to provide resistance that will allow the factory installed controller to recognize the trailer/hydraulic brakes. A technician also advised that a work around would be to wire in small magnets to the wiring of the trailer to provide the resistance. The forums state that this occurs with trailers five years or older for which there are thousands on the road. This limitation/defect applies to the majority of trailers being towed on the highways today. Failure to advise drivers of this limitation/defect and the intermittent sequencing of the disconnection leaves non-professional, recreational drivers at significant risk of brake failure while towing up to nearly 30,000 pounds. NHTSA should investigate why standard after-market brake controllers have no issues of this kind while the "supposedly" state-of-the-art new vehicle controllers are limited. It is my understanding that this same issue is found with GM and possibly RAM products.

Brake controller error. Towing a small 6500lb trailer the ford is only intermittently sending signal to the camper brakes. Error "trailer brake fault". Makes stopping at times take a longer distance. Is a potential safety concern and definitely causes wear on the ford itself. Unfortunately my Ford wasn't covered by a previous recall for this known issue even though it was made in August of 2021.

Today I was getting ready to blow some snow out of my driveway and had to move my truck. It's normally parked at a slight incline where putting it in park is usually sufficient and have never needed to use a parking brake. When I re-parked the truck, I had to put it in 4WD to get up in the driveway because we had a lot of wet slushy snow. So after I get it parked, I put it back in 2WD, put it in park, and turn off the ignition. I then got out of the truck and started over to the snow blower to get back to work. I suddenly started seeing the truck rolling backwards as if it was in neutral (which is was not). I was running towards the truck to try and jump in and stop it, and then it suddenly stopped on it's own. But I bet it rolled back a good 3 or 4 feet before it finally stopped. It actually set off the alarm system in the truck, which was no surprise rolling that far. I feel this is definitely a safety issue because if a small child was behind the truck, or even myself, it could have been disastrous.

When connected to 5th Wheel trailer, trailer brakes strength is very weak. Even when increasing the trailer braking gain up to 10 still not completely stopping trailer.

I see there is a software recall update on trailer brake controller but not sure if that is the issue. The manual squeeze brakes did not work first time 5th wheel hooked up. The 7 pin trailer clip goes into a 5 pin harness and a 2 pin harness. The 2 pin is the brake control for the trailer. I traced the wiring to the next connector.. When the wiring was unplugged and replugged in the connection and braking system worked. It is located on driver side next to spare tire. The error was happening on both the truck bed 7 pin connector and hitch connector. So issue had to be in line. The manual squeeze trigger had power because unconnected error shows on dash when squeezed and not prior to that. This puts the issue between trigger and connector split the two 7 pin trailer tow connectors. Also since the trailer is grounded to truck via the hitch it means the positive wire in that connector is the issue.