Converting hydraulic trailer brakes to electric is often driven by cost savings, simplified maintenance, and improved compatibility with tow vehicles, especially those already equipped with advanced electric brake controllers. The process involves replacing the hydraulic actuator with an electric brake controller, swapping hydraulic brake lines for appropriate wiring, and potentially replacing the brake assemblies themselves, depending on their condition and the conversion kit’s requirements.
Why Convert to Electric Trailer Brakes?
Hydraulic trailer brakes, while effective, can be complex and more expensive to maintain than electric brakes. They rely on a hydraulic actuator – often surge brakes – which responds to the deceleration of the tow vehicle. This system requires regular maintenance, including checking fluid levels, bleeding air, and potentially replacing the actuator itself.
Electric trailer brakes, on the other hand, offer a simpler, more reliable system. They operate by receiving an electrical signal from the tow vehicle’s brake controller, which then activates electromagnets within the brake assembly to apply the brakes. This system generally requires less maintenance and is more easily integrated with modern tow vehicle technology, such as anti-lock braking systems (ABS) and integrated trailer brake controllers. Furthermore, electric brakes often provide more precise braking control and modulation, especially when paired with a quality brake controller.
Assessing the Suitability of Your Trailer
Before embarking on the conversion process, it’s crucial to assess the suitability of your trailer for electric brakes. This involves considering several factors:
- Trailer Weight: Electric brakes are generally suitable for trailers weighing over 3,000 pounds (1,360 kg). Consult your local regulations regarding trailer brake requirements based on weight.
- Axle Capacity: Ensure the existing axles are rated for the desired load. Electric brake kits are typically designed for specific axle capacities.
- Wiring Condition: Inspect the trailer’s existing wiring for damage or corrosion. You’ll need a clean and reliable power and ground connection for the electric brakes to function properly.
- Brake Assembly Condition: Examine the existing hydraulic brake assemblies. If they are heavily worn or corroded, replacing them with new electric brake assemblies may be more cost-effective and ensure optimal performance.
- Tow Vehicle Compatibility: Ensure your tow vehicle is equipped with a compatible electric brake controller and a 7-pin wiring harness. This is the standard connection for electric trailer brakes.
The Conversion Process: Step-by-Step
The conversion process involves several key steps:
Disconnecting the Hydraulic System
- Disconnect the Hydraulic Actuator: Start by disconnecting the hydraulic actuator, typically located on the trailer tongue. Remove the bolts or fasteners securing it to the frame.
- Drain the Brake Fluid: Carefully drain the brake fluid from the hydraulic lines. Dispose of the fluid properly according to local regulations.
- Remove Hydraulic Lines: Disconnect and remove all hydraulic brake lines running to the brake assemblies. Cap the ends of the lines temporarily to prevent further dripping.
Installing Electric Brake Assemblies
- Remove Hydraulic Brake Assemblies (If Necessary): If you’re replacing the existing hydraulic brake assemblies, remove them from the axles. This may involve removing wheel bearings and seals.
- Install Electric Brake Backing Plates: Install the new electric brake backing plates onto the axle flanges. Ensure they are properly aligned and securely fastened.
- Install Drums/Rotors: Reinstall the brake drums or rotors, along with the wheel bearings and seals. Pack the bearings with fresh grease before installation.
- Adjust Brake Shoes: Adjust the brake shoes so they are properly positioned within the drums or rotors. This ensures optimal braking performance.
Wiring the Electric Brakes
- Run Wiring: Run appropriately sized wiring from the trailer’s junction box to each brake assembly. Secure the wiring along the trailer frame to prevent damage or chafing. Use 12-gauge wire for brake power and a suitable ground connection.
- Connect Wiring to Brake Assemblies: Connect the wiring to the electric brake magnets on each brake assembly. Polarity is not usually an issue with electric brake magnets.
- Connect Wiring to Junction Box: Connect the wiring to the trailer’s junction box, following the wiring diagram provided with the electric brake kit. Ensure proper connections for brake power, ground, and brake controller signal.
- Install Breakaway Switch: Install a breakaway switch and battery on the trailer tongue. This provides emergency braking in the event of trailer separation from the tow vehicle. Connect the breakaway switch to the electric brake circuit.
Testing and Adjustment
- Connect to Tow Vehicle: Connect the trailer to the tow vehicle and ensure the 7-pin connector is properly connected.
- Test Brakes: Test the electric brakes using the tow vehicle’s brake controller. Gradually increase the brake controller gain until the trailer brakes are properly engaged.
- Adjust Brake Controller: Adjust the brake controller settings to achieve optimal braking performance. This may involve fine-tuning the gain, ramp-up time, and other parameters.
- Road Test: Conduct a road test to verify the brakes are functioning properly under various driving conditions. Make any necessary adjustments to the brake controller settings.
Frequently Asked Questions (FAQs)
FAQ 1: What tools are required for this conversion?
The necessary tools include a wrench set, socket set, screwdrivers, wire strippers, wire crimpers, pliers, a multimeter, a hydraulic line wrench (if removing hydraulic lines), a brake spring tool, and a wheel bearing packer. A torque wrench is crucial for tightening bolts to the manufacturer’s specifications.
FAQ 2: Can I reuse my existing brake drums/rotors?
If your brake drums or rotors are in good condition (no excessive wear, cracking, or warping), you may be able to reuse them with new electric brake assemblies. However, it’s generally recommended to replace them for optimal performance and safety, especially if they have seen heavy use with the hydraulic system.
FAQ 3: What size wiring should I use for the electric brakes?
12-gauge wire is typically recommended for the brake power circuit. The ground wire should be the same gauge as the power wire. Refer to your electric brake kit’s instructions and local regulations for specific wiring requirements. Using undersized wiring can lead to voltage drop and reduced braking performance.
FAQ 4: How do I choose the right electric brake controller?
Consider the tow vehicle’s capabilities and the trailer’s weight. Proportional brake controllers are generally preferred as they apply braking force proportionally to the tow vehicle’s deceleration. Inertia-based and time-delayed controllers are also available. Read reviews and consult with a professional to determine the best option for your needs.
FAQ 5: What is a breakaway switch, and why is it important?
A breakaway switch is a crucial safety device that applies the trailer brakes automatically if the trailer becomes detached from the tow vehicle. It is required by law in many jurisdictions. The breakaway switch is connected to a small battery on the trailer and activates the electric brakes in an emergency.
FAQ 6: How do I properly adjust the electric brakes?
Adjust the electric brakes by turning the brake adjuster star wheel until the brake shoes lightly drag against the drum or rotor. Back off the adjuster a few clicks until the wheel turns freely with minimal drag. Repeat this process for each brake assembly.
FAQ 7: What causes electric brakes to lock up?
Lockup can be caused by several factors, including an overly aggressive brake controller setting, improperly adjusted brake shoes, or a faulty brake magnet. Inspect the brake assemblies and adjust the brake controller accordingly.
FAQ 8: Can I convert surge brakes to electric brakes?
Yes, this article outlines the method for converting surge brakes (hydraulic) to electric brakes.
FAQ 9: Do I need a special license to install electric trailer brakes?
Generally, a special license is not required to install electric trailer brakes. However, it’s essential to have a good understanding of electrical and mechanical systems. If you are not comfortable performing the work yourself, it’s best to hire a qualified technician.
FAQ 10: How often should I inspect and maintain electric trailer brakes?
Inspect your electric trailer brakes regularly, at least annually, or more frequently if you tow frequently or in harsh conditions. Check for wear on the brake shoes, inspect the wiring for damage, and ensure the brake controller is functioning properly.
FAQ 11: What are the advantages of proportional brake controllers over time-delayed controllers?
Proportional brake controllers provide more precise and responsive braking because they apply braking force in proportion to the tow vehicle’s deceleration rate. Time-delayed controllers, on the other hand, apply braking force gradually over a set period. Proportional controllers generally offer smoother and more controlled braking, especially in emergency situations.
FAQ 12: What is involved in wiring a 7-pin trailer connector?
The 7-pin trailer connector provides connections for tail lights, turn signals, brake lights, running lights, reverse lights, brake controller signal, and a 12V power supply. Refer to a wiring diagram to ensure proper connections. Incorrect wiring can damage the tow vehicle’s electrical system and the trailer’s braking system.