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Old 07-25-2014, 03:54 PM   #1
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Wire to break away switch

The wire to my brake controller has frayed and separated. So I was wondering what would be the best way to replace it. As always I greatly appreciate any assistance.

John
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Old 07-25-2014, 04:25 PM   #2
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Two terms: Break-away Switch and Controller..... 2 different things. Which do you mean? Your brake controller is in your tow vehicle and is wired through the umbilical. Your Break-away Switch is located on the trailer tongue. Can you post a pic of the problem?
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Old 07-25-2014, 07:58 PM   #3
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I cam unable to pst a picture however it is the wire to the breakaway switch on the trailer that frayed and separated
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Old 07-29-2014, 11:28 AM   #4
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I also have the same problem with a frayed cable to the switch on the trailer tongue. I know you can buy a replacement cable and pin at most RV parts places, but I was never really clear on how this cable should best be run to minimize damage and optimize safety should a break-away occur? Any help would be appreciated.
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Old 07-29-2014, 11:53 AM   #5
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The breakaway switch is very inexpensive, best to replace the entire switch, its only two bolts and two wires. The new switch comes with a new cable. I bought one from Vintage Trailer Supply.


There's lots of opinions on the correct way to route and connect the breakaway wire. Here's mine:

The breakaway switch is intended to activate the trailer brakes if the trailer separates from the tow vehicle. If the trailer is still attached in any way to the truck (ie. safety chains) you can still control trailer brakes with the brake controller. If the Trailer totally separates from the Truck you want those brakes on!

So you want enough slack in the cable that the pin doesn't pull out in a turn, but not so much that it can drag on the ground or get tangled in the hitch, safety chains etc. You also want the cable attached to part of the tow vehicle that is not part of the hitch.

I route my cable through the pad lock on the trailer coupler and attach it to an eye bolt I installed to replace one of the licence plate bolts (read that on the internet somewhere ) This way if the entire hitch falls off the truck, or the hitch head breaks and the safety chains fail, the pin will be pulled. My cable is long so I put a 6" loop in the cable and secured it with a small plastic zip tie. This way in a tight turn if the cable binds it can pull the loop out and not pull the pin.
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Old 07-30-2014, 10:21 AM   #6
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Thanks so much for the insight. The solution I thought I'd try is a product called Zip Breakaway Cable and Pin (6 feet).

The product is described as follows: At last, a breakaway cable that won't drag! If you are tired of frayed and broken breakaway cables, the Fastway® Zip™ is a must for you. The coiled cable keeps itself off the ground and out of harm's way while towing. Connects and removes quickly and easily with included carabiner. Available in 4' and 6' lengths, with or without switch.

We'll see how this works
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Old 07-30-2014, 02:04 PM   #7
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We have the Fastway now installed and the original one removed from a new AS two weeks ago. PM me your address and I will send it to you.
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Old 08-02-2014, 09:03 AM   #8
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Thanks but I also just installed the Fastway cable. I think it will be a good solution.

Have a great day.
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