Umair Gaines
Converting from surge brakes to electric brakes is a highly debated topic, especially for boat trailers. The main concern is that saltwater can be very destructive to brakes if left on them, and electricity and water don't mix. However, some people argue that electric brake systems are always exposed to moisture and still function just fine. To convert from surge brakes to electric brakes, you will need to remove the old hydraulic equipment, including the surge coupler or actuator, all the lines, and the brake assemblies. You will then need to install new electric brake assemblies, connect the power wires, and potentially install a new coupler. It is important to choose a brake controller that is compatible with electric over hydraulic brakes, such as the Tekonsha Prodigy P3 Trailer Brake Controller.
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What You'll Learn
Remove old hydraulic equipment
To remove the old hydraulic equipment, you will need to remove the surge coupler or actuator, all the lines, and the brake assemblies. If you have 10-inch diameter hub and drums, you will need to replace them. If you have 12-inch hub and drums, you can reuse them as long as they are in good condition.
The first step is to decide what to do with the hydraulic actuator on the tongue. You can either weld it up solid or remove it and have a fab shop install a better hitch plate or channel on the tongue for a coupler. You will then need to add a breakaway battery and switch.
Next, you will need to remove the old coupler. This can be done by locking out the surge coupler so that it cannot move in and out or by disconnecting the brake lines. Removing the old coupler will also require removing the brake lines.
Finally, you will need to remove the brake assemblies. This will involve taking out the old hydraulic equipment, including the surge coupler or actuator and all the lines.
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Install new electric brake assemblies
To install new electric brake assemblies, you will first need to remove the old hydraulic equipment. This includes the surge coupler or actuator, all the lines, and the old brake assemblies. If your trailer has 7 wires running back to the brakes, you can tap into the existing wiring. Each new brake will have two wires: one for ground and one for 12-volt power to the brake magnets. The wires are non-polarity specific, so it doesn't matter which wire is used for which function.
Next, you will need to install your new electric brake assemblies. The specific steps will depend on the make and model of your trailer and the electric brake assemblies you have purchased. However, some general steps may include:
- Mounting the electric brake controller to the trailer draw bar, ensuring that one side or edge of the device is parallel to the ground.
- Drilling holes for mounting the controller and using a drill bit of the appropriate size.
- Connecting the electric brake controller using a smartphone app or by following the wiring diagram and guide provided with the controller.
- Testing the connection by pressing down on the tow vehicle's brake pedal.
- Adjusting the electric brake assemblies as needed, using a brake adjustment tool.
It is important to note that without a brake controller, your trailer's electric brakes will not function, and towing without one would be unsafe. Additionally, it is recommended to check and clean the bearings and replace them if necessary during the installation process.
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Use an electric-over-hydraulic actuator
Upgrading your trailer's surge brakes to an electric-over-hydraulic braking system can be done by following these steps:
Firstly, it is important to ensure the trailer is securely lifted and supported on jack stands before beginning any maintenance or repairs. Next, remove the old hydraulic equipment, including the surge coupler or actuator, all lines, and the brake assemblies. If you have 10-inch diameter hubs and drums, these may need to be replaced, whereas 12-inch versions can be reused if they are in good condition.
The next step is to install the electric-over-hydraulic actuator. The Carlisle HydraStar is a recommended unit, with part # HBA-10 for trailers with drum brakes, and part # HBA16 for trailers with disc brakes. The actuator will need to be connected to the brake line that previously ran to the surge coupler.
After installing the actuator, you will need to install a brake controller. The Tekonsha Prodigy P3 Trailer Brake Controller, # 90195, is a recommended option, but it is important to ensure that the chosen controller is compatible with electric-over-hydraulic brakes.
Finally, you will need to install new electric brake assemblies, such as part # 23-105 and part # 23-106. These assemblies feature two wire leads, one for ground and one for power, and the wires are non-polarity specific. The two power wires will need to be connected and run up the length of the trailer frame.
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Choose a compatible brake controller
When converting from surge brakes to an electric over hydraulic braking system, it is important to choose a brake controller that is compatible with electric over hydraulic brakes. The Tekonsha Prodigy P3 Trailer Brake Controller, # 90195, is a proportional brake controller that is easy to use and competitively priced. It is recommended for use with electric over hydraulic brakes.
It is important to note that not all brake controllers are compatible with electric over hydraulic systems. For example, the Tekonsha PowerTrac brake controller, # 39523, is not compatible with this type of system.
If you have a 2016 Ford F-150, the factory brake controller is compatible with electric-over-hydraulic brakes. Additionally, if you have a 2022 GMC Sierra 3500, the integrated brake controller has a hydraulic mode that will work with electric over hydraulic actuators without the need for an adapter.
When choosing a brake controller, it is also important to consider the type of brakes you have. If you have drum brakes, you will need a different controller than if you have disc brakes. For drum brakes, the Carlisle HydraStar HBA-10 is recommended, while for disc brakes, the Carlisle HydraStar HBA16 is the suggested option.
By choosing a compatible brake controller and considering the specific requirements of your vehicle, you can ensure a successful conversion from surge brakes to an electric over hydraulic braking system.
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Check hub and drum sizes
When converting surge brakes to electric brakes, checking the hub and drum sizes is a critical step to ensure proper function and safety. Here are the steps to follow:
First, you need to identify the correct hub and drum sizes for your trailer. The hub and drum sizes can vary depending on factors such as the trailer's weight, axle type, and manufacturer. Consult your trailer's documentation or contact the manufacturer to obtain the specific hub and drum size requirements for your trailer. This step is crucial, as using incorrect sizes can lead to improper brake function and potential safety hazards.
Once you have identified the required hub and drum sizes, it's time to inspect your current setup. Start by measuring the diameter of the trailer's hubs. This measurement is crucial, as it determines the proper fit for the electric brake components. Ensure you take accurate measurements to match the new electric brake system appropriately.
Next, assess the drum size. Measure the diameter and width of the brake drums currently installed on your trailer. It is important to ensure that the new electric brake components will fit within the existing drum assembly. Again, accurate measurements are essential to guarantee compatibility and optimal brake performance.
After obtaining the measurements, compare them to the specifications of the electric brake system you plan to install. Ensure that the hub and drum sizes are compatible with the electric brake components. This includes checking the size of the brake shoes or pads, as well as the overall dimensions of the brake assembly. It is imperative to choose electric brake components designed to fit your specific hub and drum sizes.
If you find any discrepancies or require adjustments, there are a few options available. First, you can consider hub-and-drum assemblies designed specifically for electric brake conversions. These assemblies offer a straightforward solution by providing components that are compatible with electric brakes while ensuring proper sizing. Another option is to explore custom-made solutions or adaptors that can facilitate the installation of electric brakes on your specific hub and drum setup.
In conclusion, checking the hub and drum sizes is a vital step when converting surge brakes to electric brakes. By following the steps outlined above, you can ensure that you obtain accurate measurements, identify compatible electric brake components, and explore appropriate options for any necessary adjustments. Remember, safety should always come first, so take your time, double-check measurements, and choose high-quality components designed for your specific trailer setup.
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Frequently asked questions
First, you will need to remove the old hydraulic equipment. Remove the surge coupler or actuator, remove all the lines, and finally remove the brake assemblies. If you have 10-inch diameter hub and drums, you may need to replace them. You will then install your new electric brake assemblies.
One benefit of converting to an electric braking system is having control over the braking action and avoiding downhill lock-ups caused by surge brakes.
There are several good brands of electric brake controllers, including Tekonsha, which has been recommended by multiple sources.
There are differing opinions on this matter. Some people believe that electricity and water do not mix and therefore advise against using electric brakes in saltwater. Others argue that electric brake systems are always exposed to moisture and still function fine. However, it is recommended to disconnect the power before backing into the water.
You will need to decide what to do with the hydraulic actuator on the tongue. You can either weld it up solid or remove it and install a better hitch plate or channel on the tongue for a coupler. Additionally, you will need to add a breakaway battery and switch, and ensure that your hubs are re-installed or replaced.
