Umair Gaines
Electric brakes are becoming increasingly popular for their advanced features, adaptability to trailers, and varying tow weights and driving conditions. While converting hydraulic brakes to electric brakes involves many steps and requires basic familiarity with power and hand tools, electrical wiring, and elbow grease, it can be performed by a non-professional. The conversion entails replacing the hydraulic backing plates with electric versions and removing all hydraulic lines, replacing them with electrical wiring. This guide will provide a step-by-step introduction to converting vehicle brakes to electric brakes.
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What You'll Learn
Electric brakes are safer and more adaptable
Electric brakes are becoming increasingly popular for their advanced features and adaptability. They are also considered safer than conventional brakes.
Firstly, electric brakes are more adaptable to the particular trailer being towed and varying tow weights and driving conditions. They can be controlled by a brake controller, which enhances safety and control when braking. This device helps to control the braking force of a trailer by sending a signal to the brake actuator, which applies the brakes on the trailer. The driver can also regulate the amount of time delay between the tow vehicle driver’s foot hitting the brake pedal and the trailer’s brakes engaging. This can be useful in certain traffic conditions, such as when controlling trailer sway.
Secondly, electric brakes offer greater convenience and ease of use. Being operated by a button or switch, they are easier and more comfortable to use than mechanical brakes, which require physical effort to apply. They can also provide greater precision in the application of braking force, which is useful when fine control of vehicle speed is required.
Thirdly, electric brakes can have an automatic release function that automatically activates when the vehicle is accelerated, which is useful in heavy traffic. They may also include additional safety functions, such as automatic emergency braking and collision avoidance.
Finally, electric brakes can be more cost-effective in the long run, despite higher initial costs and more expensive maintenance and repair. They can also be more reliable, with brake pads lasting at least twice as long as they do in conventional vehicles, for 80,000 miles or more.
In conclusion, electric brakes offer a range of benefits that make them a safer and more adaptable option than conventional brakes. While there may be some challenges in converting to electric brakes, the advantages in terms of performance, convenience, and safety make them a worthwhile investment.
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Converting hydraulic brakes to electric is a complex process
Firstly, the trailer should be securely lifted and supported, ideally using a hydraulic lift to provide easy access to the underside. All four wheels need to be removed from the trailer to expose the hubs/drums. On each hub/drum, there is a dust cap that must be removed by tapping it from different sides with a mallet. With the dust caps removed, the large nuts securing the hubs/drums can be loosened, and the hubs/drums themselves removed, exposing the hydraulic brake backing plates.
The next step is to locate and loosen the hydraulic line connections to drain the brake fluid. All hydraulic lines must then be removed and replaced with electrical wiring. This includes connecting the brake controller in the truck, the electric-over-hydraulic brake actuator on the trailer, and the hydraulic disc brakes on the wheels of the trailer. Wiring and pressure lines are necessary to connect these components. The brake controller is wired into the truck, and the brake actuator is wired into the trailer's 7-pin connector. High-pressure lines are installed between the brake actuator and the disc brakes on each wheel.
In an electric system, a battery independent of the tow vehicle provides an electrical current to the brakes when triggered by the separation of the trailer. A brake controller inside the tow vehicle's cabin regulates the electrical signal and current that engage the trailer braking system. This allows for the recognition of the force applied to the brake pedal and adjusts the power to the drums accordingly.
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Electric over hydraulic brakes are superior to electric brakes
One of the primary advantages of electric-over-hydraulic brakes is the significant reduction in electrical connections at the hubs, minimising potential issues caused by debris and corrosion. The electrical connections stop at the brake booster, reducing the risk of electrical faults, which enhances the overall reliability of the trailer on the road.
Additionally, electric-over-hydraulic brakes provide stronger stopping power compared to electric brakes. The hydraulic system allows hydraulic fluid to flow directly to the brakes, generating equal and full force to all wheel positions, resulting in consistent and efficient braking. This setup provides superior performance and makes maintenance easier.
The conversion from hydraulic to electric brakes is a complex process that involves replacing hydraulic components with electrical ones. However, it can be performed by non-professionals with basic familiarity with tools, electrical wiring, and mechanical work.
In summary, while electric brakes are initially cheaper, electric-over-hydraulic brakes offer better performance, reliability, and lower long-term costs, making them a superior choice, especially for those in the hotshot trucking industry or anyone using trailers extensively.
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Removing the wheels is the first step in conversion
Removing the wheels is the first step in converting vehicle brakes to electric. This is a complex process that requires a basic understanding of car mechanics, power and hand tools, and electrical wiring. It is important to ensure that you have the necessary knowledge, skills, and tools before attempting any car modifications.
To begin, find a safe place to park your car, away from traffic and with enough space to work. Engage the parking brake, place a backstop under the diagonal wheel, and use wheel chocks or bricks to prevent the car from rolling. You should also put on your reflective jacket and set up a warning triangle to alert oncoming drivers.
The next step is to jack up the car. Consult your car's manual to identify the correct jacking points, and use a scissor jack or trolley jack to slowly raise the vehicle. Ensure that the car is stable and secure before proceeding. Once the car is raised, use a flat screwdriver or the flat end of a lug wrench to remove the hubcap and expose the lug nuts. Place the hubcap in a safe location to avoid scratches.
Now, you can start to remove the lug nuts. Use a lug wrench or a socket set to turn the lug nuts counterclockwise and loosen them. If they are difficult to loosen, apply a liquid thread loosener or rust remover and try again after a few minutes. Be cautious as the wheel may shift during this process, and watch your fingers to avoid injury. Remove the lug nuts in a star pattern, rather than sequentially, for better stability.
With the lug nuts loosened, you can now lift the wheel. Grip the back of the tire and pull it towards you to remove it from the lug studs. Be careful when handling the tire, as a damaged tire may have metal wires protruding. Place the wheel in a safe location, ensuring it does not roll away.
At this stage, all four wheels should be removed, exposing the hubs/drums. You can now proceed with the next steps of the conversion process, which involve replacing the hydraulic components with electric ones. Remember to refer to a detailed guide specific to your vehicle for the subsequent steps.
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Electric brake controllers can regulate time delay
Electric brake controllers are an increasingly popular option for vehicles due to their advanced features and adaptability to different trailers, tow weights, and driving conditions. One of the key advantages of electric brake controllers is their ability to regulate time delay, which refers to the amount of time between the tow vehicle driver depressing the brake pedal and the trailer brakes engaging.
The time delay feature is important because it allows for more control over the braking process, particularly in situations where a slight delay between the tow vehicle and trailer braking is desirable, such as controlling trailer sway or in certain traffic conditions. This delay can help prevent one component from working harder than the other, ensuring more even wear on the brakes and tires over time.
To convert hydraulic brakes to electric, several steps must be followed. Firstly, all four wheels must be removed from the trailer to expose the hubs/drums. Next, the hydraulic backing plates need to be replaced with electric versions, and all hydraulic lines must be removed and replaced with electrical wiring. This process requires a basic understanding of power and hand tools, electrical wiring, and a non-professional with some mechanical inclination can perform it.
When using a time-delayed brake controller, the driver can adjust the gain setting to accommodate each specific trailer. The gain setting determines the amount of power applied to the trailer brakes, and it can be adjusted based on the trailer and load size. For larger trailers, a higher gain setting is recommended, while a lower gain setting is suitable for smaller trailers to avoid brake lockup. It is important to note that the time-delay approach may not be as precise as the proportional method, which activates the trailer brakes simultaneously and with the same intensity as the tow vehicle brakes.
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Frequently asked questions
Electric brakes are more adaptable to the particular trailer you are towing and varying tow weights and driving conditions. They also provide a smoother braking experience, as the truck and trailer stop together evenly without one stopping the other.
In an electric system, a battery independent of the tow vehicle provides an electrical current to the brakes when triggered by the separation of the trailer.
The conversion process involves replacing the hydraulic backing plates with electric versions and removing all hydraulic lines, replacing them with electrical wiring.
First, remove all four wheels from the trailer to expose the hubs/drums. Then, take off the hydraulic brakes, remove the hydraulic lines, and install electric brake assemblies. Run a wire from the brakes into the harness.
One potential issue is the concern of what happens if the battery dies. If the battery goes dead while the parking brake is applied, the brake may not release, causing the car to roll away.
