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Northstar, was the low voltage measured by using the manual brake lever? If so, you got lucky that Ziegler isn't up on all the bulletins. All the TBC built prior to 3/23/05 have this same "feature". Ford considers it normal, per a bulletin. But they still changed this "feature" starting 3/23/05. I found this out when I tried to get mine replaced. Ford says replacement will be on me, not warranty, because there is nothing wrong. Technically they are correct because applying brakes with the brake pedal does send the proper voltage to the brakes. If I were in Indiana right now I'd be headed to Ziegler to complain about my TBC and see if they'd replace it for me. Not having the voltage applied via the manual lever makes it much more difficult to pop the slider on our hitch. Fortunately I rarely need the slider anyhow.
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