Otis Singleton
Adding electric brakes to a trailer is a straightforward process, but it's important to ensure that your trailer is compatible and that you have the necessary parts and tools. Electric brakes can be added to a trailer with or without existing brakes, and they typically offer a more cost-effective solution compared to hydraulic brakes. However, it's crucial to check the legal requirements and ensure your trailer meets the necessary safety standards, as some states may require a break-away safety kit to activate the electric brakes if the trailer becomes separated from the towing vehicle.
Characteristics and their corresponding values for adding electric brakes to a trailer
| Characteristics | Values |
|---|---|
| Difficulty | Straightforward, but requires some mechanical knowledge |
| Cost | Varies; electric brakes are generally less expensive than hydraulic brakes |
| Time | Can be installed in an afternoon |
| Requirements | Axle must have a brake mounting flange; wiring from the front of the trailer to the trailer brakes; a break-away safety kit; connectors, zip-ties, wire clips, electrical tape, and ground screws; a 7-way connector |
| Maintenance | Ensure sufficient grease in the hub assembly to prevent overheating |
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What You'll Learn
Check the axle for a brake mounting flange
For a 3-inch axle, you will need the Brake Mounting Flange for 3" Round Axle, part # 4-44-1. This brake flange will allow brake assemblies with a bolt pattern of 5 on 3-7/8 of an inch to be mounted. It will work with 7,000 and 7,200 lbs axles. The inner diameter of the flange is 2-3/4 inches. This is because the flange will be mounted to the spindle, not the axle.
If your axle is smaller than 3 inches, or you want a 4-hole mounting flange, you will need a different brake mounting flange. For a 2-3/8" axle, you will need the Brake Mounting Flange part # 4-35. For a 3-1/2" axle, you will need the Trailer Brake Mounting Flange part # 4-50. This flange has an inner diameter of 3.01 inches.
It is recommended to have a professional welder perform the task of welding the brake mounting flange to the axle. The degree of the mounting flange will need to be the same on both sides.
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Prepare the wires and connectors
When preparing the wires and connectors for electric brakes on a trailer, it is important to ensure you have the right type and gauge of wire, as well as a good ground connection.
Firstly, you will need to determine the correct gauge of wire for your trailer's electric brake system. A gauge of 14 is recommended as a minimum, as this provides an allowable ampacity for 20 amps of current at 30 degrees Celsius ambient temperature, which is sufficient for most electric brake systems. However, for longer trailers, a heavier gauge wire may be necessary, with some sources recommending a 10-gauge wire.
Once you have the correct gauge of wire, you will need to cut and strip the wires to the appropriate length, following the specific instructions included with your unit. You will need to connect one of the wires to the brake controller output wire on your trailer connector. This wire supplies power to the brake magnets, so ensure it is connected correctly. The other wire will need to be grounded to a clean metal surface on the trailer. A good ground connection is essential for the safe operation of your electric brakes.
To ground the wire, you can use a self-tapping bolt and drill it through the frame of the trailer. Connect the ground wire to the bolt, ensuring a secure connection. For the connector, you can use a butt connector to join the wires from the brake assemblies, and then use electrical silicone, heat shrink tubing, and electrical tape to secure and insulate the connection.
It is important to note that you may need to upgrade your trailer connector to a 7-way connector to accommodate the additional brake functions. Additionally, always refer to the specific instructions and diagrams provided with your electric brake kit, as the wiring process may vary slightly depending on the manufacturer and your trailer's configuration.
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Attach the wires to the brake assembly
To attach the wires to the brake assembly, you will need to run wiring from the front of your trailer to your trailer brakes. This will carry electric power to the brakes. You may also need connectors, zip ties, wire clips, electrical tape, and ground screws.
Each brake assembly should have two wires coming out of the back. Attach one of these wires to the trailer for the ground. The ground wire is important for your brakes, break-away kit, and lights. You can use the ground wire for your lights and drill a bolt through the frame to create a sufficient ground for your break-away kit and electric brake assemblies.
The other wire will receive power. It doesn't matter which wire you use for which purpose. Run a 10-gauge wire (with blue insulation) from the front of the trailer to one of the trailer brakes. This will be your power wire. Connect the power wire to the non-grounded wire on one of the brakes, then run another wire from the power wire on this brake to the brake on the other side of the axle. If you have more than two brakes, run power to all of them in the same way.
You can also run a white wire (ground) from one brake assembly to the other and connect it to one of the wires on each assembly. Then, take another white wire and connect it to both white wires for each brake assembly. You should have one wire going to a butt connector, with two white wires coming out the other side, one for each brake assembly.
Finally, you will need to set up your tow vehicle with a brake controller and the proper wiring.
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Install a breakaway safety kit
A breakaway safety kit is designed to bring a trailer to a safe stop by activating the electric brakes if the trailer disconnects from the tow vehicle during transit. This type of safety system is required in most states for trailers weighing more than 3,000 lbs (or 2,000 kg).
To install a breakaway safety kit, follow these steps:
- Mount the breakaway switch to the trailer frame: The breakaway switch is the brains of the operation. It determines when the breakaway system is activated. It should be securely mounted to the trailer frame, with the cable connected to the vehicle's frame or bumper. The cable can be attached in several ways, but the most common method is to route the pin through the safety chain loops on the hitch or bumper and then through the cable loop.
- Connect the breakaway battery: The breakaway battery provides power to the trailer brakes if needed. It should be wired into the trailer's electrical system to keep it charged. The battery is typically housed in a breakaway battery box, which is mounted on a secure surface inside one of the trailer frames in the front of the trailer.
- Splice the wires: Splice one of the wires coming out of the breakaway switch into the trailer brake wire running from the trailer connector to the brakes. Connect the second wire from the switch to the brake wire (usually blue) coming out of the battery box. This will provide power to the breakaway switch.
- Ground the breakaway kit: It is important to have a good ground for your breakaway kit. You can use the existing ground wire (usually white) running from the trailer connector to the trailer, or you can screw the ground wire directly into the trailer frame.
- Test the system: Once everything is connected, test the breakaway safety kit to ensure it is functioning properly. Ensure that the breakaway switch is activated when the trailer is disconnected from the tow vehicle, and that the electric brakes are engaged when the switch is activated.
By following these steps, you can install a breakaway safety kit for your trailer, providing an additional layer of safety and ensuring compliance with legal requirements.
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Set up a brake controller in the tow vehicle
To set up a brake controller in the tow vehicle, you will need to ensure that your trailer's axle has a brake mounting flange attached behind the hub assembly on each side. Most axles have these, but if yours does not, you can either replace the axle with a properly-rated one that has brake flanges welded in place or opt for a surge brake system, which does not require a controller in the truck.
Once you have confirmed that your trailer axle has the necessary brake flanges, you can proceed with the installation of the electric brake controller in your tow vehicle. The specific steps may vary depending on the type of vehicle and controller, but here are some general guidelines:
- Consult the manufacturer's instructions for your brake controller. This will help you understand the specific requirements and steps needed for a successful installation.
- Connect the brake controller to the tow vehicle's battery or electrical system. This will provide the power necessary to operate the electric brakes.
- Mount the brake controller in a convenient and accessible location within the tow vehicle. This could be under the dashboard or in another easily reachable area.
- Run wiring from the brake controller to the trailer connector. This wiring will carry the electrical signal from the controller to the trailer brakes.
- Ensure that your trailer connector is compatible with electric brakes. You may need to convert it to a 7-way connector that includes a circuit for electric brakes.
- Test the brake controller and trailer brakes to ensure proper functionality. Follow the manufacturer's instructions for testing procedures and adjust the settings as needed.
It is important to note that the brake controller should be set up to match the weight of your trailer and the sensitivity of the brakes. This will ensure that the brakes engage properly and provide sufficient stopping power without being too aggressive.
Additionally, always refer to local laws and regulations regarding trailer brakes. For example, in Kansas, it is required by law to have a break-away safety kit that will activate the electric brakes if the trailer becomes separated from the tow vehicle.
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Frequently asked questions
You will need electric brakes, a brake controller, and the proper wiring. You may also need connectors, zip ties, wire clips, electrical tape, and ground screws.
First, ensure your trailer's axle has a brake mounting flange attached behind the hub assembly on each side. If not, you can replace the axle with a properly-rated one that has brake flanges welded in place. Next, run wiring from the front of your trailer to your trailer brakes to carry electric power to them. Finally, set up your tow vehicle with a brake controller.
Electric brakes are usually less expensive than hydraulic brakes.
