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Post Info TOPIC: Brake fade and need to adjust van brakes?


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Brake fade and need to adjust van brakes?


Long story but I will try to keep it as short as I can.

  1. In this instance I was towing with a BF Falcon fitted with Tekonsha Primus brake controller
  2. After several hours of towing I experienced a disturbing brake fade. There was no traffic around but I had recently experienced a circumstance where I'd braked hard.
  3. Seeing the mechanic the next day he found the brake fluid was >4% hydroscopic which could explain the vapour in the brake lines causing the fade. He bled and replaced the brake fluid. Still I was concerned as to why the fluid had gotten so hot. This was a new van and our maiden voyage.
  4. The new van is smaller than our old. It is an Avan Cruiseliner around 1100kg. But here's the thing. When I was attempting to calibrate the brake controller I was not able to make the van brakes lockup by setting the gain to max (unlike our old Jayco Expanda). Instead I could feel a steady reassuring pull coming from the van brakes when triggered manually (lever on the brake controller) that brought the entire rig to rest comfortable (and without using the tug brakes). I had assumed this was normal and satisfactory.
  5. So my question is, does this suggest that the van brakes need adjusting such that should I be running through the Tekonsha procedure I am ABLE to lock up the wheels? Then back off the brake controller gain a notch or two? This would mean that I have maximum braking capacity through the van without it locking up. Also means the tug is doing less work and brakes / brake fluid won't get so hot.
  6. It is all a bit hard to explain in this forum post but hopefully the post below with the controller and brake adjustment should help clarify what I am trying to put into words.

https://www.youtube.com/watch?v=x-MkpQRUz1M



-- Edited by Elecmuso on Sunday 31st of July 2022 02:47:08 AM

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Interesting.

I have had a similar experiences this tour with our brakes, I just can not get the caravan brakes right.

I am thinking our 20 year old Hayman Reece trailer brake controller is the problem.

Our trailer brakes are all good, maybe adjustment now, the ute is well maintained, no question there.

I hope we get some really helpful replies to work with.



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Greg, when you mention 'new van', is it new or new to you. If new from a dealer, yes take it back and get the brakes checked.
If new to you, may be the brakes need adjusting.
In my personal experience, getting the brake controller to work like it should in the instructions
was a never never.
Ended up settling for a manual override. What I mean by that is that I would increase the
brake bias to the van as we came to a stop, albeit most of the time. If just slowing down no so much
but when it came to stopping, I would feel for the van to brake and feather the adjustment.
This was 3.5t rated van being pulled by a 200 series Landcruiser.
Maybe some of the new digital brake controllers may work better or can be more finely
adjusted.
If you van has drum brakes, they are all the same. The assumption is made that it was
built correctly with the proper size drums and magnets for the size of the van.
Larry

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It sounds as if the brakes on the caravan are adjusted to tight, and are causing drag. This will het up the brake drums - possibly to the point where they are already overheating before you apply the brakes. Jack the caravan and check that the wheels spin freely. If not, adjust the brakes until they do.

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Elecmuso wrote:

 

I think a new brake controller a porportional crontoller like the Tekonsha P3 are very good

I have a P3 and love it, everytime I hook up the caravan I reset according to the instructions, the large manual lever is easy to locate and use.

Its more than likely I'll get a bit of heat from this statement, but the biggest issue with overheating brakes is automatic transmissions because there is a heavy reliance on brakes, unless you learn to change down gears rather than heavy braking, because I have a manual I am using the gearbox to slow the combination down before breaking. In particular when decending hills I use the correct gear to decend, and use short controlled applications of the overide lever using the caravan brakes to slow the rig down, 2 or 3 applications of the caravan brakes and then 1 of ute so not to overheat the Ute brakes.



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deverall11 wrote:

Greg, when you mention 'new van', is it new or new to you. If new from a dealer, yes take it back and get the brakes checked.
If new to you, may be the brakes need adjusting.
In my personal experience, getting the brake controller to work like it should in the instructions
was a never never.
Ended up settling for a manual override. What I mean by that is that I would increase the
brake bias to the van as we came to a stop, albeit most of the time. If just slowing down no so much
but when it came to stopping, I would feel for the van to brake and feather the adjustment.
This was 3.5t rated van being pulled by a 200 series Landcruiser.
Maybe some of the new digital brake controllers may work better or can be more finely
adjusted.
If you van has drum brakes, they are all the same. The assumption is made that it was
built correctly with the proper size drums and magnets for the size of the van.
Larry


 New to me. It is about 12 years old and purchased privately. Though I think it is in excellent condition, it could be that the brakes have never been adjusted since new.



-- Edited by Elecmuso on Sunday 31st of July 2022 04:26:48 PM

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erad wrote:

It sounds as if the brakes on the caravan are adjusted to tight, and are causing drag. This will het up the brake drums - possibly to the point where they are already overheating before you apply the brakes. Jack the caravan and check that the wheels spin freely. If not, adjust the brakes until they do.


 Will check.



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Gundog wrote:
Elecmuso wrote:

 

I think a new brake controller a porportional crontoller like the Tekonsha P3 are very good

I have a P3 and love it, everytime I hook up the caravan I reset according to the instructions, the large manual lever is easy to locate and use.

Its more than likely I'll get a bit of heat from this statement, but the biggest issue with overheating brakes is automatic transmissions because there is a heavy reliance on brakes, unless you learn to change down gears rather than heavy braking, because I have a manual I am using the gearbox to slow the combination down before breaking. In particular when decending hills I use the correct gear to decend, and use short controlled applications of the overide lever using the caravan brakes to slow the rig down, 2 or 3 applications of the caravan brakes and then 1 of ute so not to overheat the Ute brakes.


Yes good point re: downhill driving. Something I'm aware of but should do more. However in this case I had been driving around the suburbs for nearly an hour at mostly <50kph. Admittedly it COULD be that the brake heat buildup was initiated some time before I made it into the suburbs and was kept hot by frequent stopping / starting in traffic (which was particularly frequent being school pickup peak hour).



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When i recently bought my 2nd hand van i removed the drums to find the wrong seal had been installed & leaked grease every where. I replaced the entire system, drums shoes backing plate & magnets. Brakes now work great. It pays to check any 2nd hand vans brake system for peace of mind.

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Are you using gears,engine breaking ? I try not to use brakes too long !! Plus the speed at the top of the hill should be what it is at the bottom . I try to leave my brakes for emergencies. The controller needs adjustment!! Or if cable ? A little looser .. as said I find engines breaking more Subtle..

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If buying a used caravan one would be wise to fit new brake pads and repack the wheel bearings.
Automatic transmissions are designed to accelerate and to hold momentum, not for braking - that's what brakes are for.
And repairing brakes is a lot cheaper than repairing an automatic transmission.
However if someone can show me a vehicle manufacturer which recommends using engine braking I will reconsider.
Towing a caravan downhill using engine braking seems a lot less stable than using brakes with a break controller. For a start the caravan is pushing the tug via the tow-ball while the tug is trying to go slower; not unlike pushing a brick around with a stick.

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jegog wrote:

If buying a used caravan one would be wise to fit new brake pads and repack the wheel bearings.
Automatic transmissions are designed to accelerate and to hold momentum, not for braking - that's what brakes are for.
And repairing brakes is a lot cheaper than repairing an automatic transmission.
However if someone can show me a vehicle manufacturer which recommends using engine braking I will reconsider.
Towing a caravan downhill using engine braking seems a lot less stable than using brakes with a break controller. For a start the caravan is pushing the tug via the tow-ball while the tug is trying to go slower; not unlike pushing a brick around with a stick.


 Use the same gear to descend a hill as you go up the hill, in a manual that easy to know as you change the gear to go up, In an auto the gear box just keeps downshifting untill it get up the hill, going down that same hill you will need to identify the correct gear, to prevent overheating brakes.

A good example is Macquarie Pass, that decends the Great Dividing Range from Robertson (great pie shop there) down to the NSW south coast, towing a caravan up the pass more than likely you would be switching between 2nd and 3rd gears, decending the Pass if you left your transmision in drive by the time you reached the bottom of the pass your brakes would red hot and smoking. There you would manually select 3rd in the auto transmission to slow the decent possibily choose 2nd in some of the steeper sections also using controlled braking.

When we came down the pass I left my manual in 2nd gear, using the electric brake controllers manual overide to slow the caravan inertia, alternating between the all and caravan only breaking application.



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Its no harder on autos to use them manually . Thats why its there and thats why you have licences to drive heavy vehicles . If your over heating brakes ? Its set up wrong or your doing it wrong ! To think we travel with people that potentially over heat their brakes !! Only worry about costs !! Ive been to too many accidents !! Driving like sports with van off the back !! Slow down and take it easy !! Btw autos fail if not pulled down in gears going up hills . Usually sports mode or overdrive cut out ? The ECU doesnt know you have van on back , plus it keeps the engine in its efficient rpm range . Again if you rely on vehicle to do that ? Maybe you shouldnt be towing ? 40 kph down some steep hills should be for towed vans also .

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Elecmuso wrote:

Long story but I will try to keep it as short as I can.

  1. In this instance I was towing with a BF Falcon fitted with Tekonsha Primus brake controller
  2. After several hours of towing I experienced a disturbing brake fade. There was no traffic around but I had recently experienced a circumstance where I'd braked hard.
  3. Seeing the mechanic the next day he found the brake fluid was >4% hydroscopic which could explain the vapour in the brake lines causing the fade. He bled and replaced the brake fluid. Still I was concerned as to why the fluid had gotten so hot. This was a new van and our maiden voyage.
  4. The new van is smaller than our old. It is an Avan Cruiseliner around 1100kg. But here's the thing. When I was attempting to calibrate the brake controller I was not able to make the van brakes lockup by setting the gain to max (unlike our old Jayco Expanda). Instead I could feel a steady reassuring pull coming from the van brakes when triggered manually (lever on the brake controller) that brought the entire rig to rest comfortable (and without using the tug brakes). I had assumed this was normal and satisfactory.
  5. So my question is, does this suggest that the van brakes need adjusting such that should I be running through the Tekonsha procedure I am ABLE to lock up the wheels? Then back off the brake controller gain a notch or two? This would mean that I have maximum braking capacity through the van without it locking up. Also means the tug is doing less work and brakes / brake fluid won't get so hot.
  6. It is all a bit hard to explain in this forum post but hopefully the post below with the controller and brake adjustment should help clarify what I am trying to put into words.

https://www.youtube.com/watch?v=x-MkpQRUz1M



-- Edited by Elecmuso on Sunday 31st of July 2022 02:47:08 AM


 As just about usual these replies to the post are as useless as tits on a bull.

Can we get some real answers on brake controllers please.



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On mine . I adjust using tug brakes . Add % till I feel brakes working better ! Mine has an inertia setting also . So it works a little with deceleration



-- Edited by Aus-Kiwi on Tuesday 2nd of August 2022 11:11:04 PM

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Really my main question is summarised in point 5. And I am leaning towards yes the brakes need to be adjusted to make up for some brake shoe wear. Thereby making them more sensitive and able to be locked up when the gain is set too high (and subsequently backed off to the point where they don't lockup). This is how the manual says it should be done and is how I previously calibrated the brake controller gain for my previous van.

So who has adjusted their own brakes as per this YouTube video?

https://www.youtube.com/watch?v=3cOyJ9ELoxg



-- Edited by Elecmuso on Wednesday 3rd of August 2022 12:07:00 AM

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Just to be clear this video shows the model of brake controller that I have and how to set the gain.

https://www.youtube.com/watch?v=x-MkpQRUz1M



-- Edited by Elecmuso on Wednesday 3rd of August 2022 12:00:10 AM

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jegog wrote:

If buying a used caravan one would be wise to fit new brake pads and repack the wheel bearings.
Automatic transmissions are designed to accelerate and to hold momentum, not for braking - that's what brakes are for.
And repairing brakes is a lot cheaper than repairing an automatic transmission.
However if someone can show me a vehicle manufacturer which recommends using engine braking I will reconsider.
Towing a caravan downhill using engine braking seems a lot less stable than using brakes with a break controller. For a start the caravan is pushing the tug via the tow-ball while the tug is trying to go slower; not unlike pushing a brick around with a stick.


 Might I suggest that the modern Auto transmissions have an *S* mode which provides the driver with the function to use the transmission in manual form.

To suggest that this is harmful to the transmission is incorrect but I wont go into the technical side of the operation of the modern automatic.

Having said this, using the auto trans as part of the function of engine braking when descending a hill should be considered as a normal operation which would be used by a driver with the skill to actually be towing a caravan.

Driving and towing a caravan with a car involves a lot more than what may be covered by blanket statements.

Using the same gear to go down a hill as you might use to go up it is good basic advice.

To rely on using the caravan brakes to descend a hill might easily result in complete brake fade well before the vehicle gets to the bottom of the hill and it is at the bottom of the hill where the brakes may be needed the most.

Almost every situation can be different and with each situation it will require the need for special skills in driving the combination. The sooner a licence is required for towing a caravan, the safer we will all be.

Almost all caravans have drum brakes  and *pads* are only used when disc brakes  are used. It is common safe practice when overhauling brakes on a caravan is to replace the entire assembly of backing plate, brake shoes and linings, magnets and ancilliary parts and wiring on all wheels at the same time.

Doing this ensures that all wheels are braking equally when fitted and adjusted correctly.

It should be illegal for the average Joe or Judy to tinker with brakes and more so when those do not know what they are doing.

If you have trouble with your brakes then seek the advice of a qualified person rather than the *expertise* of some on a forum who may or may not know what they are talking about.

 



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Elecmuso wrote:

Just to be clear this video shows the model of brake controller that I have and how to set the gain.

https://www.youtube.com/watch?v=x-MkpQRUz1M



-- Edited by Elecmuso on Wednesday 3rd of August 2022 12:00:10 AM


 That video is not of the Tekonsha P3 proportional brake controller that you stated you have 9 postings above! confuse



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BaldEd wrote:

 That video is not of the Tekonsha P3 proportional brake controller that you stated you have 9 postings above! confuse


I never said a Tekonsha P3. Gundog did (and somehow misquoted me). Have a look at MY posts - they all mention the Primus model (except the one where I quote Gundog).

 

Hence why I posted the YouTube link. To make it clear!



-- Edited by Elecmuso on Wednesday 3rd of August 2022 03:50:48 PM

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I think you are pushing Tekensha products

 The original poster could be a troll



-- Edited by Plain Truth on Wednesday 3rd of August 2022 06:33:16 PM

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I am the original poster and I cannot understand why you would think that! I've not pushed the product in any way.

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Elecmuso wrote:

I am the original poster and I cannot understand why you would think that! I've not pushed the product in any way.


 Take no notice of the ravings Greg, some get carried away.

To answer your question, I always adjust my van brakes as per the video, can't say that I wind them in 8 notches , I adjust so there is no contact of drum and pad when spinning several times. Never had any issues with brake operation.

Chris.



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Elecmuso wrote:

I am the original poster and I cannot understand why you would think that! I've not pushed the product in any way.


 Hi Greg. First of all, welcome to the forum, where you'll find a wealth of knowledge among your fellow members. Don't allow some of the strange 'logic' displayed by other members to make you despondent, as it usually is the intent of many here to help you, although sometimes that doesn't seem to be the case! Let's hope that you are successful in sorting your brakes, but it's all a bit beyond me! I use Towpro Elite which I've found to be great. Cheers



-- Edited by yobarr on Wednesday 3rd of August 2022 08:35:31 PM

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The Travelling Dillberries wrote:
Elecmuso wrote:

I am the original poster and I cannot understand why you would think that! I've not pushed the product in any way.


 Take no notice of the ravings Greg, some get carried away.

To answer your question, I always adjust my van brakes as per the video, can't say that I wind them in 8 notches , I adjust so there is no contact of drum and pad when spinning several times. Never had any issues with brake operation.

Chris.


 Thanks for the reassurance Chris. Seems like we are on the same page. What brake controller do you have?



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yobarr wrote:
Elecmuso wrote:

I am the original poster and I cannot understand why you would think that! I've not pushed the product in any way.


 Hi Greg. First of all, welcome to the forum, where you'll find a wealth of knowledge among your fellow members. Don't allow some of the strange 'logic' displayed by other members to make you despondent, as it usually is the intent of many here to help you, although sometimes that doesn't seem to be the case! Let's hope that you are successful in sorting your brakes, but it's all a bit beyond me! I use Towpro Elite which I've found to be great. Cheers



-- Edited by yobarr on Wednesday 3rd of August 2022 08:35:31 PM


 Cheers for that. Most of the comments were helpful but it only takes a couple like those to put one off. 



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Elecmuso wrote:
The Travelling Dillberries wrote:
Elecmuso wrote:

I am the original poster and I cannot understand why you would think that! I've not pushed the product in any way.


 Take no notice of the ravings Greg, some get carried away.

To answer your question, I always adjust my van brakes as per the video, can't say that I wind them in 8 notches , I adjust so there is no contact of drum and pad when spinning several times. Never had any issues with brake operation.

Chris.


 Thanks for the reassurance Chris. Seems like we are on the same page. What brake controller do you have?


 I have the Redarc Towpro. I am about to relocate it to a more accessible spot. It's down below my dangling keys so not ideal in an urgent situation.



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The Redarc Tow Pro Elite can be programmed to respond in proportion to the amount of effort the driver exerts on to the brake pedal at a given braking event so as to cause the van to slow in unison with the towing vehicle.
The unit also has the emergency feature should someone start the *one two three waltz*

They are really great technology if set up correctly.

If anyone is not skilled in brake fitting,repairs, and adjustments, then get some who is to do your repairs, after all the next time you need to stop may be your last.

Lets hope not.

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Yes its text ! Can be taken way over the top in meaning taken the wrong way ? Especially if humour is added, but doesnt extend other end ? Brakes need to be taken seriously!! They should never get to the point of fading !! Should always have some in reserve in case a car changes lanes in front of you or tighter corner than anticipated etc

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Clarky 1 wrote:

The Redarc Tow Pro Elite can be programmed to respond in proportion to the amount of effort the driver exerts on to the brake pedal at a given braking event so as to cause the van to slow in unison with the towing vehicle.
The unit also has the emergency feature should someone start the *one two three waltz*

They are really great technology if set up correctly.

If anyone is not skilled in brake fitting,repairs, and adjustments, then get some who is to do your repairs, after all the next time you need to stop may be your last.

Lets hope not.


 You can do the same with any porportional electric brake controller my Tekonsha P3 works very well.



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