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Converting Existing Hydraulic Brake System to Electric on Pop-Up Camper  


Good morning. My, new to me, popups surge brake system is shot. From the master cylinder all the way to the brake clusters are needing to be replaced. I want to go to electrics. Can you put together a parts list to do that? Also as the hydraulics are 1 3/4 and the electrics are 1 1/12 am I going to need to shim out 1/2inch to make everything line up? Or will the 1 3/4 drums Dexter Trailer Hubs and Drums - 8-173-16UC3 work to make things work without shims? Thanks guys


Expert Reply:

The Dexter Hub/ Drum you mentioned, part # 8-173-16UC3 would be a proper replacement for you as long as the inner and outer bearings in your existing hubs are # L44649, the grease seal is # 10-9 and the 4-on-4 bolt pattern matches up with your existing hubs. Your existing bearings and grease seals should have reference numbers stamped on them, make sure the numbers on the existing parts match those of the replacements.

You will also need electric brake assemblies, part # 23-47 for the left side and # 23-48 for the right. You will also need mounting bolts # 7-75, nuts # 6-17 and lock washers # 5-8, 4 of each for each brake assembly. You will need to check your existing brake mounting flange on your axle to ensure that the 4 bolt holes are spaced 2-7/8 inches apart, measured center-to-center.

Each brake assembly will have two wires exiting the magnet. One lead will be grounded to the trailer frame, the other lead will connect to a brake wire ran from the trailer connector. The trailer connector used will depend on how your tow vehicle is equipped. For a 6-way connector, I would recommend part # H20036 or part # H20046 for a -way connector. There is a table showing the wire color code on each product description page.

You will need a brake controller installed on the tow vehicle to actuate the electric brakes. The Tekonsha Prodigy P2, part # 90885 is our most popular model, because of its versatility and ease of use. Depending on your tow vehicle and how it is equipped, there might be a connector located under the dash that would make installing the controller very simple. Most late model full-sized pickups and SUVs have this provision.

If your tow vehicle is not equipped with the under-dash connector, the brake controller could be installed using one of our install kits, # ETBC6 for a 6-way connector or # ETBC7 for a 7-way connector.

If the current surge coupler you are using is still mechanically sound, you can simply leave it in place after draining the master cylinder and removing the brake lines.

If you would care to provide some details about your tow vehicle, I would be happy to provide information that would be more specific to your vehicle. Knowing he following would be helpful:

What is the year, make and model of tow vehicle?
Does the vehicle currently have a trailer connector on it?
If so, which connector does it have?

I have provided links to some FAQ pages and install videos that you might find helpful.

expert reply by:
Mike L

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