Thanks again,
Turned out to be the BR relay. #3 BR contact in the brake coil circuit would fail with no pattern or rhythm. Some times it would be weeks before it would fail. Finally I pulled the relay off the controller and opened the coil & armature up. When I did some debris fell and hit my foot. Looking at the contacts there is some burn. But there is a needle like tip formed on the contact. As if the contact metal heated up and was drawn the follow the arch across the contacts. I'll post a picture if I can figure out how.
Thanks again Brett for you suggestions. Your a good Mate...
