Converting Trailer from Surge Brakes to Electric Brakes

Question

Question:

i have a trailer that is currently fitted w/ 2 sets of surge brakes. my new chevy truck has a controller built in. what will it take to convert my trailer?

asked by: will

0

Expert Reply:

First you will need to remove the old hydraulic equipment. Remove the surge coupler or actuator, remove all the lines, and finally remove the brake assemblies. If you have 10 inch diameter hub and drums, you may need to replace those as well. If you have 12 inch hub and drums, you can re-use them so long as they are in good shape.

You will install your new electric brake assemblies, like part # 23-105 and part # 23-106. The magnets have 2 wire leads, one for ground, one for power. It does not matter which wire you use for which function, they are non-polarity specific. The two power wires will need to be run up the length of the frame and connected together. Ultimately they need to connect to the brake controller output wire on the 7-Way on the truck. I have added a link to a wiring page that shows which pin serves which function on a seven way.

Hubs need to be re-installed or replaced. This would also be a good time to clean and check bearings and make sure they do not need to be replaced. I have added links to a bunch of videos that show how to do these things.

You will need a new coupler and this all depends on the frame of the trailer. I have added a link to a page with all of our couplers on it.

This should get you started for now. You will probably have more questions later, so feel free to write back and we will do our best to get you set up.

expert reply by: Patrick B

0

Jerry

6/8/2025

Hi Patrick, I’m looking to convert 1102 Humvee trailer. I’d appreciate you let me know what all the steps do I need to take? I wanna convert it to a 12 V system. My sprinter has a seven pin pigtail. I want to install an articulated hitch. Also, I want to convert the surge to electric brakes. Thanks looking forward to your response.

Jameson C.

6/9/2025

@Jerry First thing to determine is the capacity of the axles on the trailer and the wheel bolt pattern. If since it's a Humvee and uses non-standard axles we'd need to get the spindle dimensions where the bearings ride or the bearing numbers out of the hub. I attached a link to a page on adding electric brakes to a trailer for you to check out as well.

Helpful Links

faq-adding-electric-drum-brakes.aspx

Thomas

6/18/2025

Patrick, I have 2 3500lb axles on a pontoon trailer. I am considering switching the surge system to electric because I just cant seem to get the surge system to work in a way that the hubs don't get extremely hot during a tow. Only the real axle has the brakes. I have 10" hubs/drums but you mention that if 10" I may have to replace them, why? the ones I have are only 2 years old. Also, what do I do with the actuator?, leave it and just lock it out with the adapter? it is fairly new as well however I don't think the internals (master cylinder/shock are new)

Jon G.

6/18/2025

@Thomas You can swap over to the 10" etrailer Electric Trailer Brakes # AKEBRK-35-SA which works with drums that are 10" diameter x 2-1/2" wide - so just measure your hub interior and you'll be able to determine fitment. You'll need to lock out the actuator and run 10 Gauge Wire # 10-1-1 from the 7-Way to the electric brakes. Plus, you'll need to install a breakaway kit # 3802346 for safety. I'm also attaching a link to our help article on adding electric drum brakes to a trailer for you to check out.

Helpful Links

faq-adding-electric-drum-brakes.aspx

Answer 1

You can convert surge brakes to an electric over hydraulic braking system. To do this, you will need an electric over hydraulic actuator and a brake controller. For an electric over hydraulic actuator, I recommend looking at the Carlisle HydraStar…

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Answer 2

Finding the correct electric brakes for your M416 military trailer will depend on a few things. First will be the axle capacity. I did a lot of looking, but I couldn't find this listed anywhere. Due to the weight and carrying capacity, odds are…

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Answer 3

Hello John, thanks for reaching out. Generally the brake line would be coiled inside the stationary part of the tongue, so you can pull it out and service it when needed. If you are unable to pull the line out to replace it, I am afraid there is…

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Answer 4

In almost all cases 3,500 lb axles will all use the same bearings. If your trailer has a Lippert or Dexter 3,500 lb axle then yeah they would be the same. But to be safe it won't hurt to pull them off and get the numbers. If you are sure you need…

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Answer 5

Let's start with the brake controller. My personal recommendation is for the Tekonsha Prodigy P3, #90195. This is a customer favorite because of how easy it is to setup and how well it works. Now for the wiring. Although your 2008 Monaco Knight…

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Answer 6

Since you have checked it out and are unable to find a wire at the top of your brake pedal, you will need to find a dedicated circuit as you described. If your third brake light only works when the brakes are applied you can use that wire for your…

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Answer 7

Traditionally, trailer manufacturers did not use electric brakes on boat trailers because the brake magnet wiring and trailer wiring did not always have the best insulation or water protection. These days, more and more manufacturers are using…

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Answer 8

Hey Erik, unofficially I have a solution for that with the Bright Way Trailer Breakaway kit part #3802336. This is a pretty small battery in a box you could run your converter box to instead of all the way up to the vehicle battery but I have to…

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Answer 9

All of that is not necessary. All you have to do is lock out the surge coupler so it cannot move in and out or disconnect the brake lines. By removing the old coupler you would have to remove the brake lines any way. A surge coupler can still be used…

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Answer 10

Thank you for the image of your setup Steve. I do not know what the manufacturer was thinking when they welded in the Demco Actuator on your boat trailer. With how it was installed there is no way for you to access that rear pin without drilling a…

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Answer 11

Thank you for reaching out and the photos! From what I'm seeing it looks like you need the Dexter Axle Disc Actuator 12.5K #T4749620 or 20K #T4750520 depending on the weight rating of your current actuator. These have similar coupler features,…

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Answer 12

I would be happy to help, but I have no way of looking your trailer by the serial number to determine which replacement side mount jack is correct. Based on the picture you provided of the jack on your Dorsey Malibu Boat Trailer a standard bolt on…

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Converting Trailer from Surge Brakes to Electric Brakes

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