Umair Gaines
Converting a vehicle axle to electric brakes can be a complex process, and it is important to understand the different parts involved and the steps required. The process involves adding compatible parts such as flanges, spindles, brake assemblies, hubs, drums, and brake controllers. The type of vehicle and trailer will determine the specific parts and tools needed, and it is crucial to refer to a professional guide or mechanic for the exact specifications. This conversion can provide improved performance and greater stopping power, combining the control and response time of electric brakes with the power of hydraulic brakes.
Characteristics and Values Table for Converting Vehicle Axle to Electric Brakes
| Characteristics | Values |
|---|---|
| Brake System | Electric over hydraulic |
| Parts Required | Electric over hydraulic actuator, brake controller, flanges, spindles, brake assemblies, hubs, drums, brake magnet, wiring, breakaway kit |
| Axle Type | Dexter axle with brake mounting flanges |
| Axle Capacity | 3,500 lbs |
| Wheel Bolt Pattern | 5 on 4-1/2 |
| Axle Length | 89 inches (hub face to hub face) |
| Spring Center Distance | 74 inches |
| Brake Controller | Compatible with electric-over-hydraulic brake actuators |
| Wiring | Connect power wire to non-grounded wire on one brake, run wire to other brakes, use hangers and zip-ties, wrap connections with electrical tape |
| Compatibility | Ensure brake controller is compatible with electric over hydraulic actuators |
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What You'll Learn
Identify the type of brakes you want
Electric brakes are a convenient upgrade to a vehicle, offering improved braking performance and greater stopping power. When considering an electric brake conversion, it is important to identify the type of brakes you want. Here are some factors to consider:
Electric Over Hydraulic Brakes
One option for electric brake conversion is to go with electric-over-hydraulic brakes. This type of system combines the control and response time of electric brakes with the stopping power of hydraulic brakes. Electric-over-hydraulic brake systems are known for their performance and power. To install this type of brake, you will need an electric-over-hydraulic actuator that is compatible with your vehicle's brake controller. This actuator is typically mounted on the trailer, and it receives electric signals from the controller to activate the trailer's hydraulic brake lines.
Electric Drum Brakes
Electric drum brakes are a common choice for trailers and can be added to a trailer that doesn't already have brakes. This type of brake is relatively easy to install and typically involves adding compatible parts such as flanges, spindles, brake assemblies, hubs, and drums. You will also need a brake controller to operate these brakes effectively. Electric drum brakes are often more affordable than other options and can be a more common system to work with.
Electric Disc Brakes
Another option is to go with electric disc brakes, which offer even greater stopping power and performance compared to electric drum brakes. Disc brakes have fewer moving parts, which makes them more efficient and requires less maintenance over time. To install electric disc brakes, you will need to ensure that your trailer's axle has a brake mounting flange attached behind the existing hub assembly on each side. This type of brake may be more expensive but can provide superior braking capabilities.
State Laws and Regulations
It is important to consider any state laws or regulations that may impact your brake conversion. Some states have specific requirements for the number of brakes needed based on the gross vehicle weight rating (GVWR) of your vehicle. Be sure to check and comply with any relevant laws to ensure your vehicle remains road legal.
By considering these factors, you can make an informed decision about the type of electric brakes you want for your vehicle axle conversion. Each option has its advantages, and choosing the right one will depend on your specific needs, budget, and vehicle compatibility.
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Check compatibility with brake controllers
When converting a vehicle axle to electric brakes, it is crucial to ensure compatibility with a suitable brake controller. This process involves several key steps, including understanding the braking system requirements, selecting the appropriate controller, and verifying compatibility with the vehicle and trailer setup.
Firstly, it is important to understand the braking requirements of your vehicle and trailer. Different countries have varying legal requirements for braking systems, especially when it comes to weight and axle configurations. For instance, certain weight thresholds mandate having an efficient braking system on at least one axle or all wheels. Electric brakes are commonly recognised as an "efficient braking system", and they are often found on camper trailers and caravans. Therefore, it is essential to familiarise yourself with the relevant regulations to ensure compliance and safety.
Next, you should select a brake controller that is compatible with your specific setup. There are several types of brake controllers available, including electric brake controllers, air brake controllers, and electric-over-hydraulic (EOH) brake controllers. Electric brake controllers, such as the Elecbrakes system, can be easily installed on any trailer and are compatible with a wide range of vehicles. They are designed to operate with 12V and 24V voltage systems and can control up to two braked axles. Additionally, Elecbrakes offers a wireless, trailer-mounted solution that provides flexibility and control without requiring modifications to the vehicle.
However, if you are dealing with a truck or semi-tractor that has air brakes, you will need a compatible brake controller. Options like the Prodigy P3 or the Hayes Air Actuated Trailer Brake Controller can work with air brakes and electric trailer brakes. It is worth noting that some brake controllers are not designed for electric-hydraulic settings, so be sure to check the manufacturer's specifications.
Finally, when checking compatibility, it is important to consult the manufacturer's instructions and resources. For example, Hydrastar provides a compatibility sheet on their website, which can help you determine if your rig and controller are compatible. Additionally, the manufacturer of your tow vehicle or trailer may have specific recommendations or requirements for brake controllers, so it is worth reaching out to them for guidance.
By following these steps and considering the unique aspects of your vehicle and trailer setup, you can ensure compatibility with the appropriate brake controller when converting a vehicle axle to electric brakes.
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Select the right electric over hydraulic actuator
To select the right electric-over-hydraulic actuator, it is important to understand the components and functionality of such a system. Electric-over-hydraulic actuators are a key component in converting between electric and hydraulic braking systems, allowing for the benefits of both systems.
The electric-over-hydraulic actuator is typically mounted on the trailer and is responsible for receiving electric signals from the tow vehicle's brake controller and applying pressure to the trailer's hydraulic brake lines. This results in improved braking performance and greater stopping power compared to traditional electric brakes.
When selecting an electric-over-hydraulic actuator, compatibility is crucial. Ensure that the actuator is compatible with disc brakes and can be installed on the tongue of the trailer frame. Additionally, check for plug-in connectors that can simplify the installation process. Some actuators also include breakaway kits, which are essential for trailer safety in the event of uncoupling from the tow vehicle. These kits typically include a battery, wiring, and sometimes a built-in charger. It is important to choose a breakaway kit that meets the minimum size requirements specified by the actuator.
Furthermore, consider the type of brake controller that works best for your needs. Some actuators come with portable or remote brake controllers that communicate via radio waves and can be plugged into a power source in the cab of the tow vehicle. These remote controllers offer convenience and flexibility when switching between different tow vehicles. Ensure that the brake controller you choose is compatible with electric-over-hydraulic actuators.
Lastly, pay attention to the materials used in the brake lines. Steel brake line tubing is often preferred over rubber due to the high pressures generated by electric-over-hydraulic actuators. By considering compatibility, installation ease, safety features, brake controller options, and material choices, you can make an informed decision when selecting the right electric-over-hydraulic actuator for your vehicle axle conversion to electric brakes.
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Install the brake mounting flange
To install the brake mounting flange, you will first need to identify the type of axle you have. This is important because not all axles are created equal, and the process of adding electric brakes may vary depending on the specific type of axle you are working with.
Once you have identified the type of axle, you can begin the process of installing the brake mounting flange. This typically involves removing the existing wheel and brake assembly to access the axle. With the wheel and brake assembly removed, you can then clean and prepare the axle surface to ensure a secure and proper fit for the new brake mounting flange.
The next step is to carefully align and position the new brake mounting flange onto the axle. This step may require some measurements and adjustments to ensure that the flange is correctly centred and level. It is important to follow any manufacturer instructions or guidelines provided with the brake mounting flange kit for the specific type of axle you are working on.
After the flange is properly aligned, you can then begin the process of securing it in place. This typically involves using bolts or other fasteners to attach the flange to the axle. Again, it is important to refer to the manufacturer's instructions for the specific type of fasteners and torque specifications required.
Finally, with the brake mounting flange securely in place, you can then re-install the wheel and brake assembly, ensuring that all components are properly connected and secured. At this stage, it is crucial to perform a thorough inspection of your work and ensure that all components are securely fastened and functioning properly before operating the vehicle.
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Wire the brakes
To wire the brakes, you will need to set up a tow vehicle with a brake controller and the proper wiring. The brake controller sends a signal to the brakes when the brake is pressed in the towing vehicle. You will need to replace the 4-way connector at the front of your trailer with a 7-way that includes a connection to carry power to the brakes.
The first step is to 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. If possible, run the wire through openings in the frame, and use hangers and zip ties to route the wire. Keep the wire close to the bottom of the trailer, so it doesn't hang down and get snagged or damaged.
Use butt and quick-splice connectors to connect the wires. Wrap the wiring connections with electrical tape to keep water out. If your trailer has 7 wires running to the brakes, you can tap into the existing wiring. Each new brake will have two wires for the brake magnet: one for 12-volt power and the other to be grounded to the trailer frame or the main trailer ground wire. It doesn't matter which wire is used for power or ground as they are not polarized.
If the trailer wiring is running down the left side of the trailer, splice the left-side brake assemblies into the main electric brake power wire coming from the 7-way connector. Then, run a jumper wire from the electric brake power wire to the right-side brake assemblies. It is recommended to use 12-gauge wire for the jumper wire and for any additional ground wire.
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Frequently asked questions
Electric over hydraulic brakes provide the control and response time of electric brakes, along with the stopping power of hydraulic brakes. Disc brakes are also an option, which are more powerful and require less maintenance than drum brakes.
You will need to add compatible parts including flanges, spindles, brake assemblies, hubs and drums, and brake controllers. You will also need a wiring harness and a brake controller that sends a signal to the brakes when the brake is pressed in the towing vehicle.
You will need to connect the power wire to the non-grounded wire on one of the brakes, then run another wire from the power wire 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.
A breakaway kit applies the trailer's brakes if the trailer becomes uncoupled from the tow vehicle. These systems include a battery and wiring, and sometimes a built-in charger. While not all kits include a breakaway kit, they will work with standard breakaway kits designed for electric brakes.
You will need an electric-over-hydraulic actuator and a brake controller. You will also need to lock the coupler so that it does not actuate when you are braking.
