Broken wires at brake drums

[ibosket]

I’ve had some issues with braking on the curb side of my coach for a while now, but was attributing it to needing to reset the brake controller which seemed to remedy the problem. Today however I was underneath taking care of some rust and noticed that both curb side wheels have gray wires severed at the drum! Yikes! I assume these wires activate the brakes so it probably means I haven’t had braking on that side for a while now. Has anyone else had this issue?

[dznf0g]

Perennial issue with all trailers with electric brakes.

Sent from my SM-S901U using Airstream Forums mobile app

[Bill M.]

Yes. Has happened to me several times. Big wire connects to little wire and no real way to make the connection good. Search Amazon for heat shrink connectors with step down sizing and buy a ratcheting crimper for then. I put a short intermediate wire in mine to help with the wire size change.

[DCPAS]

I fixed this same thing on my brother's trailer last week and several times on a carhauler I own.

[ibosket]

OK - thank you for the replies. I also read the similar posts that showed up on earlier threads. There seems to be good lengths hanging out to do a repair myself so I’ll try it and see how it goes. Based in all the responses that reference this is a common problem, it seems like a more reliable system could be configured in the first place! Ha! Anyway - thanks again.

[dznf0g]

My memory has faded...but there is a very flexible wire made for vibration resistance. You might splice a section in. It helps a lot with longevity. Someone help me out here with th name of that wire.

I did the swap on my old trailer and never had a break again.

Btw, you might want to carry a selection of connectors and a crimp tool along in your travel kit. There's always a need for them.

Sent from my SM-S901U using Airstream Forums mobile app

[Boxite]

multi-strand or “stranded”

[dznf0g]

Originally Posted by Boxite

multi-strand or “stranded”

Yeah, there was more to it than that. It had a real rubbery insulation. Silicone maybe, but didn't really feel like it. This was some 20 or 30 years ago. It reminded me of a fusible link, but was wire.

Sent from my SM-S901U using Airstream Forums mobile app

[Action]

On a previous trailer I used a plastic conduit. Similar to the attached picture except it was black. Worked to keep out most of the things that might cause damage.

However if the wire caught on something and got yanked the conduit would not help there.

Action

[sheriff1]

I’m going to try these with shrink over the top.

[dznf0g]

Originally Posted by sheriff1

I’m going to try these with shrink over the top.

Attachment 432445

Get the heat activated glued shrink. Water does get in these connections whatever you use.

Sent from my SM-S901U using Airstream Forums mobile app

[richard5933]

Seems like the big issue is not how you make the wire connection, it's frequent inspection to make sure that the wires have not snagged on something and gotten pulled out. I'd rather have the connection be the weak link in this event - make the connection too securely and instead of pulling out when snagged it will rip the wire apart and have it not be easily repaired.

On my new axles I incorporated a few well placed zip ties to hold the cable tighter against the axles, moving the loop for movement of the axle a bit higher up. It can still allow the axle to move without pulling on the wires, but the loop is not so susceptible to being snagged. It just takes one well-placed branch at a camp ground to snag on the wires and disable the brakes.

[kittmaster]

Check out my post

https://www.airforums.com/forums/f43...ml#post2289728, #2

[ROBERT CROSS]

Originally Posted by dznf0g

Perennial issue with all trailers with electric brakes.

Sent from my SM-S901U using Airstream Forums mobile app

Yep...even after JC replaced our axles they couldn't bring themselves to route the wires correctly...

Bob
🇺🇸

[Boxite]

Originally Posted by ROBERT CROSS

Yep...even after JC replaced our axles they couldn't bring themselves to route the wires correctly...

Bob
🇺🇸

That almost looks like mouse-chewed wires.

[dznf0g]

Originally Posted by Boxite

That almost looks like mouse-chewed wires.

Looks like a rub-through to me.

Sent from my SM-S901U using Airstream Forums mobile app

[Vantair]

Just back from a 3week 3k mile southwest US round From the start, noticed dramatically lower braking to the point having to increase the brake gain to 10!!

This was just after a fresh bearing repack before trip. (Diligently avoiding contaminating the drums from grease on this 25ft 2005 Intl. )..

Thank goodness for diesel breaking option which saved the trip.

Back home, doing a star wheel brake adjustment (all we’re off) also found 2 brake leads severed on different wheels. One had snapped off right at the grommet entering the brake assembly. Obviously all are becoming brittle with age. Or possibly the I-40 potholes?

The smaller white sheathing hardened and cracked exposing bare wire which corroded to a disconnection.
While repairing, the other lead easily pulled out from the large to smaller factory butt connection ! WOW !

Repaired all for now soldering, crimping and using Goop Marine to reinforce the brittle flexing areas but seriously considering replacing all 4 with fresh “self adjusting” Dexter brake assemblies for the combined benefit and fresh flexible leads.

Very little confidence in this Original factory chance discovery.

[Boxite]

HD sells aluminum, flexible, electrical-conduit.

https://www.homedepot.com/p/Southwir...2321/100122113

I suppose one could route the wires thru some of that and secure the ends of the conduit firmly to adjacent structure. I’ll look into that when I replace the entire brake assys next tire change.

Here’s the brake/drum assys I plan to use:
https://www.amazon.com/dp/B01555B4I6...v_ov_lig_dp_it

or

https://www.amazon.com/dp/B0155578YA...WxfdGhlbWF0aWM

[ROBERT CROSS]

Originally Posted by Boxite

That almost looks like mouse-chewed wires.

They would have had to hang on like crazy on the 400mi trip back to homebase.

First thing I did when we got back from JC.... remove all wheels ck all mounts
and torque lug nuts..."trust & verify".

Bob
🇺🇸

[Action]

Originally Posted by Boxite

HD sells aluminum, flexible, electrical-conduit. I suppose one could route the wires thru some of that and secure the ends of the conduit firmly to adjacent structure.

Using a metal conduit or sheathing can be an issue. If the wire connection were to come apart or the wire were to chafe somehow, that is creating a short on a circuit that can carry a lot of current.

If using a metal covering, use a fuse or breaker in that circuit to prevent a spark or fire.

Action