[A/S] Unusual Brake Situation

[npdigh@xxxxxxxx]

We recently upgraded from our 82 6.2 Burb to a 94 6.5.  I took the Burb and trailer (1975 AS 31') to a nearby trailer dealer (big dealer for horse & other trailers, with good reputation for service) to have a brake control installed on the Burb, to adjust the brakes and pack the wheel bearings on the trailer.  It turned out that new backer plates were needed, but the cost was reasonable and I knew that other AS owners had experienced replacing these on trailers of this age.  We have had several tow vehicles, farm vehicles, and trailers at this dealer in the past and the service has been excellent.  Stay tuned, it gets better.  We left after picking up the Burb and trailer to visit daughters in AL and FL.  First two days out, brakes worked perfect.  Third day, while attempting to exit from the interstate to a rest stop, I applied the brakes to slow down, removed my foot from the brake pedal and the trailer brakes continued to engage.  There was three distinct lunches, it felt like someone was learning to drive and rabbit hopping with the clutch.  My immediate action was to jump out and unplug the trailer from the tow vehicle, by this time we were still on the exit ramp, but out of the main traffic lane.  I called the trailer dealer on my cell phone, front counter guy tells me that I should talk to the service manager and he was at lunch, but will call me back.  By the time he called we concluded that since the trailer was unplugged from the tow vehicle overnight and it rained, perhaps there was moisture in the plug or receptacle.  We used alcohol, cotton swaps, etc to clean everything thorougly.  After this, the brakes worked and when the service manager called he said that maybe moisture was the problem and to spray the plug with WD 40.  This happened 2 more times on the 12 day trip, twice when exiting the interstate.  We were able to get brakes after each occasion, only after much frustration to continue the trip and return home.  Back home in MO, I called and explained the situation to the front counter person.  He made an appointment for me and assured me all was under warranty and there would be no additional charge.  Before taking the trailer back to the dealer, I discovered the new wires to the new backer plates were not tied up neatly and would likely get caught on something, looking closer I found one wire was already severed into.  I took the trailer and Burb to the dealer for the appointment, no appointment recorded on the books, and a different counter person who knew nothing of my brake situation and was initially less than cooperative.  As my anger began to show and I threated to depart but seek some legal advice, he decided it would be a good time for us to jointly talk to the service manager.  The service manager is a real gentleman, he waded into the middle of the fray, I reminded him that we had talked by phone during the trip and explained that it had happened two more times.  He nodded his head and calmly said "tell  me exactly what happened and I will fix it".  I am near the end!  They kept the trailer an extra two days, when I went to retrieve it I was assured that everything was OK and ready to go.  I asked the counter person if they had concluded what caused the problem.  He sheepishly said "yes, it was caused by a loose backer plate, that was causing the magnets to engage and broke one wire into".  I have only towed it about 20 miles, but brake system appears to be normal.  We will depart next week for a trip to NC, hopefully with a well working brake system.  My apology for the length of this, but as a reader of this list for several years, I have never seen this predictament discussed, hopefully it is one time occurrence!    Ned in MId MO