Electric over Hydraulic Disc Brake Conversion for 7,000 lb Nev-R-Lube Axles  

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Expert Reply:

For your 2010 Jayco Designer with 7,000 lbs Nev-R-Lube axles we have several disc brake options that will fit. The weld on flange bracket that you mentioned is only necessary if there is not a flange on the axle, since your's has a 5 bolt design, it's already installed.

There are 3 potential sizes of lug studs that mount the wheel and tire, 1/2", 9/16" and 5/8", so you want to check the size so you can use your current wheels and lug nuts. All of the kits will give you a 8 on 6 1/2" bolt pattern and work with wheel sizes 16" - 17"

If you have 1/2" studs I recommend Dexter Disc Brake Kit part # K71-694-695-10.

If you have 9/16" studs use part # K71-694-695-12.

If you have 5/8" studs use part # K71-694-695-14

Each one of the kits will have all the hardware, bearings races and seals in the kit to install on 1 axle, so since your Jayco is a tandem axle you will need 2 kits. The numbers, and measurements are as follows, :

The Inner bearing: # 25580 (1.75" inner diameter),
The outer bearing: # 14125A (1.25" inner diameter),
Inner race: # 25520,
Outer race: # 14276,
Grease seal: # GS-2250DL Inner diameter: 2.25", Outer diameter: 3.376".

Disc brakes do require more pressure from the actuator to apply the brakes, the kits require 1600 psi from the actuator to operate properly, so you will want to check and verify the psi rating of your actuator, as well as the condition of the lines.

If you need an actuator I recommend the HydraStar Vented Marine Electric Over Hydraulic Actuator for Disc Brakes part # HS381-8067. It will provide the 1600 psi you need to operate the brakes, and work with a variety of brake controllers. But the actuator will require a brake controller that is compatible with electric over hydraulic brakes, so you want to see if your brake controller is compatible.

If you need a new brake controller I recommend the Tekonsha Prodigy P2 Trailer Brake Controller part # 90885. The P2 is one of my favorite brake controllers, because it gives you a smooth proportional braking action, and is very intuitive to use and set up. It works with 1 to 4 axles, so it would be perfect for your Jayco Designer.

If you need to run new brake lines I recommend # HS496-252, the HydraStar Hydraulic Brake Line Kit for Tandem Axle trailers. It has 25' of main line, and since your Jayco is about 37' long, you'll have more than enough line to reach all the brakes.

I linked videos for you to reference.

expert reply by: Robert C

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