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Topic: Brake Safety Cable needs replacement

Posted By: mburns279 on 07/20/10 09:51am

I have had my TT for 18 months now (love it), and after our last trip, I noticed the safety cable from my emergency brake activator had been worn all the way through.

When I picked up my TT from the dealer they had woven this cable through the safety chains, and rough edges of the chains had worn through the cable.

What do you guys recommend using for this emergency switch? More thin cable? A small chain?

Do you recommend I weave it through the safety chains and just attach it with the safety chain hook to the back of my TV receiver?


Posted By: azgpsguy on 07/20/10 10:08am

I had to replace mine twice in two years due to it fraying. I found a new coiled cable called Zip breakaway cable. Has been working great, Here is the link to it.

Link


Posted By: Wheelspinner on 07/20/10 10:08am

I would not weave it through the chain or attach it in such a way to cause it to chafe against anything. I leave it free hanging, one can shorten it with a zip tie if needed. I think I would probably replace the switch, they are not that expensive, rather than mess with replacing the cable. My .02






Posted By: Jerry9n on 07/20/10 10:14am

It should not be woven through the chain. Here is a rather good set of instructions from Warner Electric.

"8. Determine the correct length for the lanyard.
The lanyard is the correct length if the following
conditions are satisfied:
Condition 1: If trailer should become disconnected,
the lanyard must become taut and
pull the pin out of the breakaway switch
before the trailer safety chains become taut.
Condition 2: If the trailer should become disconnected,
the lanyard must become taut
and pull the pin out of the breakaway switch
before the towing vehicle-to-trailer electrical
wiring becomes taut. Making the electrical
wires longer than the safety chains is a convenient
way to accomplish this.
Condition 3: During normal towing operation,
the lanyard must NOT become taut
enough to pull the pin out of the breakaway
switch when turning a corner.
Condition 4: During normal towing operation,
either straight or while turning corners,
no chains or wiring should be allowed to
drag on the ground.

Also, there is a company that makes a nifty coiled cable:


Zip Cables

I put an eyebolt on the frame with a straight cable through it then the zip cable. Simple and neat and provides a straight pull from the switch.


Jerry9n
2009 23' Cikira Escape EXP
2006 Ford Expedition
Reese Pro Series SC
Tekonsha Primus IQ
HTT Mods



Posted By: popeye59 on 07/20/10 11:27am

Jerry9n wrote:

It should not be woven through the chain.

Concur

Jerry9n wrote:

Determine the correct length for the lanyard.
The lanyard is the correct length if the following
conditions are satisfied:


Condition 1: If trailer should become disconnected,
the lanyard must become taut and
pull the pin out of the breakaway switch
before the trailer safety chains become taut.

Makes sense, though mine doesn't (I don't think it does at least, never tested it)

Jerry9n wrote:

Condition 2: If the trailer should become disconnected,
the lanyard must become taut
and pull the pin out of the breakaway switch
before the towing vehicle-to-trailer electrical
wiring becomes taut. Making the electrical
wires longer than the safety chains is a convenient
way to accomplish this.

Makes sense again, though mine doesn't (again, I don't think it does anyway)

Prolly should test both above.

Jerry9n wrote:

Condition 3: During normal towing operation,
the lanyard must NOT become taut
enough to pull the pin out of the breakaway
switch when turning a corner.

Concur

Jerry9n wrote:

Condition 4: During normal towing operation,
either straight or while turning corners,
no chains or wiring should be allowed to
drag on the ground.

Concur

Jerry9n wrote:

Also, there is a company that makes a nifty coiled cable:


Zip Cables

I put an eyebolt on the frame with a straight cable through it then the zip cable. Simple and neat and provides a straight pull from the switch.

That's what I have but I connect it to the eye holes the safety chain attaches to.


Frank and Jean
EM1 USN ret
DAV Life Member

'09 Rockwood Roo 233S
'03 1500 Silverado LS

The things that come to those that wait will be the crappy junk left by those that got there 1st.

Remember; never underestimate the power of stupid people in large groups.


Posted By: Jimehc on 07/20/10 04:10pm

Personally - I do not think the brake away switch cable should be connected to anything that could break away with the trailer... ie (Hitch, Hitch Mount, Bumper, Safety Chain or Chain Holes, etc..)

I connect the safety cable to the truck frame - the whole hitch mount may fall off - but almost sure the truck frame won't..

I have also found it more reasonable to replace the whole brake away switch - for a few dollars more then the cable itself - as they all seem to use different pins and pin styles..


Posted By: popeye59 on 07/20/10 04:27pm

If my GM installed receiver falls off causing me to need the break-away safety switch to be activated, I've got bigger issues than a trailer tumbling down the highway behind me.


Posted By: webslave on 07/20/10 06:01pm

popeye59 wrote:

If my GM installed receiver falls off causing me to need the break-away safety switch to be activated, I've got bigger issues than a trailer tumbling down the highway behind me.


X2

I also use and love the Zip Cable mentioned by a couple of posters above. Neat, clean and no chance of dragging or catching on anything. While I can see some logic in connecting it to a different point, I also agree that if my frame mounted hitch comes off, then myself, DW, and the three fur balls all have a much larger problem than the trailer catching up with us, so, it gets attached at the same point as the safety chains.


My 2 cents, your mileage may vary...

Don
Bronwyn
2 Cats; J-Lo and Ragamuffin

2011 Keystone Cougar 318SAB
2011 Ram 2500 Longhorn CTD HO
Built in brake controller and exhaust brake
Tri Glide TrailAir Pinbox with a B&W Companion Hitch



Posted By: Hgarnerno1 on 07/20/10 06:24pm

Mine became frayed to the point that only one strand was holding it together. I found a copper crimping sleeve in my deep sea fishing tackle box. I cut the cable and crimped the two ends together and wrapped it with electrical tape. Good as new, cost 00.


Howard, USN Ret
2000 Ford Excursion,V10, Limited
2003 Terry 27H. Super Slide



Posted By: Jimehc on 07/20/10 06:46pm

Most hitches are bolted to the frame and bolts do loosen and break...


Posted By: xciton on 07/21/10 10:59am

popeye59 wrote:

If my GM installed receiver falls off causing me to need the break-away safety switch to be activated, I've got bigger issues than a trailer tumbling down the highway behind me.


'Cept, if I'm driving the other direction, my issue *IS* your detached trailer.


Posted By: Doug33 on 07/21/10 12:10pm

Mine somehow got pinched hard enough to cut through it after 4 seasons of camping. Just had dealer replace it while getting axles and brakes serviced. It was a nominal cost.


2014 Keystone Bullet 281BHS
2002 Chevy Avalanche 5.3L 4x4
Equalizer hitch
Nights spent camping in 2014: 14
Next trip: late September in Lancaster PA



Posted By: RCMAN46 on 07/21/10 01:10pm

For no more than a new switch and cable costs I would just get a new switch and cable. They do deteriorate with age or if ever used. Too important of a system to pinch pennies.


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