Parts Needed to Convert From Surge to Electric Brakes

Question

Question:

I just bought this pop up with surge brakes. I asked about the brakes when I bought it as the master cylinder cap was corroded and looked like it hasnt been off in a while. He stated he has never looked into the brakes as he has always had a 3/4 or 1 ton truck he was pulling it with and didnt care. Pulled great never knew it was there. Camper was in great shape otherwise. I thought what could it take to rebuild or replace this. Well.....looking into this brake setup it would need a full rebuild and feedback on this type of braking is terrible. I want to convert to electric. Pulled off hub and without actually pulling backing plate, it appears to measure 2 3/4inch x 4. Drum 2 1/2inch deep by 10inch wide. Am I measuring these right? Doesnt seem to be a normal size. What parts do I need for converting. Thanks

asked by: Chet K

0

Expert Reply:

The backing plate you are referring to is, I'm assuming, the brake mounting flange, which should be welded on. The dimensions of this are extremely important because it will determine the brake assemblies that fit.

The Demco Trailer Brake Mounting Flange # DM60124 has a 2-3/4" pilot hole and has a 4 on 4-13/16" bolt pattern. This is uncommon compared to Brake Mounting Flange # 4-35 which is for 2-3/8" round axles and has 4 bolt holes which are 2-7/8" apart on center, which is what you can see in the photo I added. You need to know this dimension in order to get the right electric brake assemblies.

As for your drum, you are correct that 10" x 2-1/2" deep is not common though because the drum is wider than the standard 2-1/4" brake assemblies you can still use the recommended Electric Trailer Brake Kit # AKEBRK-35-SA which are 10" diameter x 2-1/4" wide so long as you have the standard 4-bolt mounting flange. These are self-adjusting brakes which are rated for 3,500 lb axles.

With that you will also need a Breakaway Kit # 50-85-313 as well as wiring on your trailer.

For your tow vehicle you are also going to need a brake controller and the appropriate wiring. For a 2004 Chevy Tahoe if you do NOT have the factory 7-way you will need to add Custom Multi-Tow 7-Way and 4-Way Trailer Connectors # 30955.

If you DO have the factory 7-way you will only need the brake controller and wiring adapter. I strongly recommend the Prodigy P3 # 90195; it is the most popular model we carry due to its effectiveness and ease of use. It will activate your trailer's brakes immediately in proportion to your Tahoe's brakes and offers three different boost levels so you can adjust your braking power. The correct wiring adapter for your Chevy is part # 3015-P.

I have also added a help article for you to check out which details all the parts you need to add electric drum brakes.

expert reply by: Kyle S

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Answer 1

So the short answer is no, there is nothing you can do to your current mounting plate to make another braking assembly fit your current setup. What you have is pretty unique, and when the team and myself took a look at it we were all in agreement…

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Answer 2

As I do not see that we currently have a trailer axle with a 93" hub face to hub face you are going to be best to have the brake flange welded in place. To ensure this is done properly you will want to find a trailer shop with a jig to ensure…

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Answer 3

I attached a picture that has the bolt pattern of the brake assemblies part #23-105-106-09 that you mentioned. This is the standard offset AL-Ko style of 4 bolt pattern.

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Answer 4

Picking out brake assemblies for trailer axles is actually pretty easy but I am not able to determine the info I need from your trailer info since it's not something manufacturers keep records of. You do need to order a total quantity of 4…

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Answer 5

To determine the size of the brake assemblies you need you have to measure the depth and width of the hub drum on the axle like what you see in the picture I attached. The most common size is 2-1/4 inch wide like the #T4071600-500 that you…

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Answer 6

Welding a mounting flange, possible item #4-35, is a very precise installation. The flanges need to be installed square and concentric to the hub and drum assembly and each other. If the flange is installed incorrectly rapid brake lining wear,…

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Answer 7

Brake mounting flange #4-50 has a standard 4 bolt pattern for 8,000 pound brake axles. Diagonally the holes are spaced 5 inches apart on center. Side to side they are 3-7/16 inches apart on center. And top to bottom they are 3-5/8 inches apart on…

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Answer 8

In order to determine the correct placement for the brake mounting flange, you will need to put all wheel components together in the proper order on the spindle and then mark the location for the brake mounting flange. The brake mounting flange needs…

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Answer 9

You have a 3500 pound axle, with a 4-bolt axle flange, spaced 4” apart each. You also have tires and wheels with a 5 on 4.5 bolt pattern. To put brakes on your West Texas Dolly #WTD-35D you will need a left and right trailer brake kit like the…

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Answer 10

The slip on kits like the part #K71-635-92 that fit your Dexter 8k axles have the benefit of rotors that are easy to replace going forward since you don't have to replace the hub at same time. Like with this kit you could replace rotors in future…

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Answer 11

The common electric brake assembly size that is 7 inches in diameter is 7 inch by 1-1/4 inches wide. The part #AKEBRK-2 matches this and would work on a 2k axle like what you have. It also mounts with a 4 bolt mounting pattern. Only issue is the…

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Answer 12

I attached a picture of a 4-bolt mounting flange like what the brake assembly part #AKEBRK-2 you referenced is designed to attach to. This is a standard dimension so I would be shocked if the flange on yours was different.

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