I just bought a 2005 chevy 2500 HD 4X4 with D/A over the weekend and i love it. Had to take advantage of the employee discount. The truck i just sold was a 2002 chevy 2500 HD with a 6.0. I took my brake controller out of that truck and put it in my new one by plugging it in to the port under the dash where it plugged in on my old truck. The problem i am having is everything works(lights, turn signals) but the green light on the controller that turns red when the brakes are applied does not turn red it just stays green. Are there wires that have to be swapped on the plug?? What am i doing wrong. I appreciate your help and this forum rocks! It is very informative and enjoyable to read..

Howie (How Dog)

You need to swap 2 wires. I think the brown? and the light blue? if I recall correctly. I know the 2 wires you need to swap are the park light wire and the brake wire but I am not 100% certain on the color and it changes depending on which brand of wiring harness you use. I also know that the 2 wires are at the opposite ends of eachother on the plug.

The way it is set up now when your park lights come on it will apply the brakes on your trailer.

You need to swap 2 wires. I think the brown? and the light blue? if I recall correctly. I know the 2 wires you need to swap are the park light wire and the brake wire but I am not 100% certain on the color and it changes depending on which brand of wiring harness you use. I also know that the 2 wires are at the opposite ends of eachother on the plug.

The way it is set up now when your park lights come on it will apply the brakes on your trailer.

Thank you for your reply.On my controller there is not a brown wire. There is a White,Black, Red and Blue. Do i need 5 wires(brown)? When i bought my 2002 all as i did was remove the controller from my 1999 and pluged it in and it worked.:help: I am going crazy over here trying to figure this out.

What about on the plug end what color wire are there? It is the plug end you have to change.

Dog,

GM changed the wire locations in 2003. THere is a simple wire swap you need to do. I have the sheet printed out in front of me..

Pre 2003 it was:

White/Red
Blank/Black
Blank/Blue

2003+ it is:

White/Blank
Blank/Black
Red/Blue

I think you can find the same info from the Tekonsha site....

Also, remember the fuse under the hood. Napa # 782-1118

Cheers.

McCoy

I will try that. I am sure that is what the problem is. I will let you know.
Thanks again,
Howie :cool2:

I'm guessing the Voyager is wired the same as the Prodigy for which the wire switching instructions were probably originally intended. If you have a little extra money, this might be a good time to lose the Voyager entirely and upgrade to the Prodigy, a much better controller.

TC

I got it to work. The wire swap was just what it needed. Thank you all for your help.
Howie:ro)

Now onto the next problem. I now installed a plug in the back corner of my truck to plug my 5th wheel into and am trying to figure out how to hook up the wires. The plug i installed has 7 wires. Black-brown-red-blue-large white-yellow and green. The truck has large black-large blue-yellow-green-lt green-large red. If i plug the trailer into the factory plug on the truck everything works. Can any of you help me with the wiring this new plug onto the existing wires of the truck? The truck is a 2005 chevy 2500 HD

Thank you
Howie

OK I am not 100% sure I understand what you are asking so I will try to help the best I can.

The first column is GM wire colors, the second column is the function of that wire and the third column is the color as it would be marked on a 7 wire plug. I hope that is what you want to do is add a 7 wire rv plug onto the existing bundled up gm wire at the front of the box? If not try to be a bit clearer.

GM wire color - Function - 7 wire rv plug label
white - ground - white
green -right turn - brown
yellow - left turn - red
brown -tail light - green
blue - brake control- blue
orange? - trailer power - black

On edit it looks like you are somewhere else. Please try to explain exactly what you are trying to acomplish and how.

Thanks for your reply. Yes i am trying to hook up the wires from the new plug in the bed into the GM factory wires that hook into the existing 7 wire plug in the trailer hitch on the bumper. I am confused as to where each wire goes. The colors on the 2005 are different than those on my 2002 so i am stumped. I think what you posted was in fact just what i needed. The only thing is my truck does not have a orange wire or a white in the loom going to the exisitng plug. I hope i am explaining it correctly.
Howie

Do you have the Towing Pkg? If so, there is a factory wire loom tucked between the box-cab. The wires are labeled. Uncoil the loom & stretch it to the rear of your truck. If you think its too short; splice & H2O proof and extension to where you want it. Drill your hole; pull the wires through & mate to the plug. The rear of your plug/recepticle should also be labled. Just match 'em up.

I do have the towing package. I do see a bundle of wires and if i trace them back they go twords the front of the truck and the other end goes into the factory plug on hitch under the bumper. The wires that are there are blue-black-yellow-green-light green-red-brown

I also have the towing package and use it as wired. But I was also told that my truck has a separate wiring harness (somewhere) for the 5er hitch. I'll see if I can find it, but it's a separate option on my sticker - 5th Whl wiring or something like that..

Ed

yup... $35 option but well worth it for me. I ran the wiring into my toolbox and have the plug in the lower middle of the box, also hooked up a rechargeable mag light and have it riveted to the upper inside of box

the wire breakdown is in the manual. I put a 6 way in my bed for my horse trailer and used the factory 7 way on the bumper to wire the plug in the bed the same way. so if i use the 6 way or the adapter to plug it in the 7way it works. the wiring diagram for the seven way is on the flip up cover.
Good Luck