Disc Brake Installation, Part Two

On our last issue, we talked about the benefits of disc brakes. We have installed a set of Hypowered disc brakes from Tow Brake International on our 30-foot Award special events trailer for a test of the system.

This is an electric-over-hydraulic system that energizes when the brake pedal of the tow vehicle is pressed and the brake lights come on. The electronic package inside the Hypower is turned on by the signal from the brake controller, and maintains the pressure on the brake fluid until the towing vehicle brake is released. This pressure is created by an electric motor-driven piston pump and electronically-controlled pressure relief valve, which is the heart of the system.

The Hypowered unit utilizes standard automotive disc brakes and is a proven system that includes a ventilated rotor and hub combined with a caliper and mounting bracket which attach to the axle end assembly by bolting to the standard brake flange.

Andy Thomson, our Hitch Hints columnist, did the disc brake installation for us. The trailer was put up on jacks and the wheels, drums, and electric brake backing plate system removed. The caliper mounting brackets were bolted to the brake flange that is welded to the trailer axle. They were installed at three o'clock on the left side and nine o'clock on the right side so that they were angled up toward the rear of the trailer. The mounting bolts were then torqued to between 40 and 50 pounds and a drop of Locktite applied.

The inner bearing and insert were greased and inserted inside the integral hub and rotor and the inner dust seal was inserted. The hub and rotor assembly was then slid onto the axle spindle. Next, the outer bearing was greased and inserted into the rotor with a flat washer. The retainer nut was hand tightened while slowly turning the rotor until the hub could not be turned. Using a wrench, the nut was slowly turned to the first point where the notches in the retainer nut would line up so that a cotter pin could be installed to lock the nut in place.
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