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Catalina/Capri 25/250 Sailor's Forums

Catalina 25 Specific Forum

Trailer Repair - surge brake system

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pbarr
1st Mate

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USA
54 Posts

Initially Posted - 06/01/2002 : 02:42:36

We have a 1978 Cat25 swing keel with a dual axle trailer.

I'm trying to find a replacement master cylinder for a 1978 cat25 swing keel trailer. Through the rust I can make out Atwood 6000 lbs GWV on the surge brake cover. The master cylinder is too rusty to read the casting number.

If anyone knows a number for the master cylinder I'd appreciate finding out. Also, If I go for replacing the whole surge brake assembly does it usually come complete with the ball hitch, shock absorber etc.. so that I can just bolt it on, hook up the brakeline, bleed and go, or will there be a lot of other "extras" to buy.

I'll have to replace the lines, rebuild the cylinders and replace the shoes. Any thoughts on getting the parts and part numbers as well as an estimate of overall costs, assuming I do the work?

I've done a lot of work on car brakes but am not at all familier with surge brakes. All experiences and comments are also appreciated.

Thanks, Phil

pbarr@umich.edu

Edited by - on

Steve Milby
Past Commodore

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USA
5902 Posts

Response Posted - 06/02/2002 : 07:36:51

Hi Phil,

I rebuilt the surge brake system on my EZ Loader Trailer last year. Your’s sounds like a different manufacturer, but it will probably be similar. I too have done a lot of work on automobile brakes (as an amateur), and you should have no trouble doing the job. It’s easier than repairing auto brakes.

Check the phone book and call several boat dealers to find out who repairs boat trailers in your area. When you find one who can get parts for your trailer, he should be able to identify the specific parts that you need. I took my trailer to him, so he could identify the manufacturer and see the old parts and identify them himself.

Because my brakes had not needed repair since the trailer was new, I decided that it was time to replace the system completely. I installed a new master cylinder (which included a new hitch and shock absorber), all new brake lines, and new brake assemblies. The brake assemblies include new wheel cylinders, new linings, and all new springs, star wheels and other hardware. On my trailer, the parts included in the brake assemblies came already mounted on a backing plate. All I had to do was unbolt the old backing plate from each wheel, and bolt on the new one. It couldn’t have been simpler. The same is true of the master cylinder/hitch/shock absorber assembly. It was a one-piece assembly, and just bolted on. To replace the brake lines, simply fish them through the same openings of the frame as the old ones, and clamp them to the frame in the same way as the old ones. Be careful not to bend or pinch the brake lines.

After all the parts have been replaced, you need to connect the brake lines to the master cylinder and to the wheel cylinders, fill the master cylinder with brake fluid, bleed the brakes and check for leaks. Each wheel cylinder has a bleeder valve, just like on a car. Since you don’t have a brake pedal to pump the brakes, you attach the hitch ball to the trailer hitch, and you use the part that goes into the hitch receiver of your tow vehicle as a lever, to pump the brakes by hand. Your new master cylinder will probably come with instructions on how to bleed the brakes.

Finally, you will probably have to adjust the new brake linings manually, because on my trailer they are not self-adjusting. (It’s hard to believe, isn't it!)

I don’t have a record of my costs for the parts, but I believe it was a bit over $400, and worth every penny of it.

Steve Milby "Captiva Wind" C-25 T/FK #2554

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OJ
Master Marine Consultant

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USA
4382 Posts

Response Posted - 06/03/2002 : 09:48:17

Phil,

try www.championtrailers.com

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Earl Landers
Navigator

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USA
157 Posts

Response Posted - 06/03/2002 : 18:44:19

Here is another source

http://www.northerntool.com

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pbarr
1st Mate

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USA
54 Posts

Response Posted - 06/04/2002 : 13:21:44

Thanks for the feedback. After checking around think that I should be able to put it back on the road for arond $400. Anyone familiar with the surge brake mechanism from "Tie Down Engineering" ? That's the one I'm considering buying. Champion trailer lists it for $109.00

Phil

pbarr@umich.edu

Edited by - on

Arlyn Stewart
Master Marine Consultant

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USA
2980 Posts

Response Posted - 06/08/2002 : 21:27:31

My Atwood needed rebuilding a couple of years ago... rebuild kits were no longer available...so I changed to a Demco actuator from Champion which in my opinion seems to work slightly better. Not sure if its rebuildable or not.

Something that was reccomended to me... and a route I went...was to convert to Dot 5 brake fluid. It is a synthetic and made to withstand higher temperatures. Thats not an issue for trailer sailors...but the fact that it doesn't attract moisture is a big plus. My first brake system lasted four years...Have two on the Dot 5 now and the fluid remains clear indicating that there is no rust or corrosion at work.

To change, the lines must be purged of all Dot 3 fluid.

Arlyn C-250 W/B #224

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Notice: The advice given on this site is based upon individual or quoted experience, yours may differ.
The Officers, Staff and members of this site only provide information based upon the concept that anyone utilizing this information does so at their own risk and holds harmless all contributors to this site.