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Necessary Components to Complete a Hydraulic Disc Brake Assembly

From Front (Tongue) to Back on Single Axle Trailer

From Front (Tongue) to Back Axle on Tandem Axle Trailer
14. Two Kodiak Disc Brake Kits with Mounting Bolts

Functions of Key Components of Trailer Disc Brake System


1. 5 Flat Wiring Harness- On Trailers Operating Disc Brakes, a 5th wire is required. This 5th Wire would be in addition to the standard 4 Flat used on trailers not operating brakes. The standard 5 Flat Wiring harness add a Blue Wire to be used. Your towing vehicle would need to be equipped with a female version of the 5 Flat or a 7 RV (very common as well). You will more often see the 7 RV plug come installed on your vehicle if you have a vehicle that is rated to tow trailers that would require brakes. If you have the 7 RV Plug, we have an adapter that has a male 7 RV to plug into your truck, and a Female 5 Flat to accept your trailers Male 5 Flat. Essentially that Blue wire is required to hook into your Reverse Lockout Solenoid (see below). 


2. Hydraulic Surge Actuator- Think of this device as a "brake pedal" for your trailer with your tow vehicle being the foot. On your vehicle, your foot initiates the braking process by depressing the brake pedal. On your trailer, the momentum of the trailer surging forward when your vehicle stops is what initiates the braking process. When the trailer surges forward towards the slowing tow vehicle, the surge actuator is compressed. There's a shock inside the Surge Actuator that absorbs this force as it exerts pressure to the Master Cylinder. All Surge actuators have a master cylinder in the rear housing. You will notice its location as it has a Cap exposed (where you fill it with hydraulic fluid). This Master Cylinder supplies the hydraulic pressure that flows through your Lines. 


3. Reverse Lockout Solenoid- This device is essential and a key ingredient for the operation of a Trailers Disc Brakes. This screws directly into the back of your Surge actuators Master Cylinder. It has a Male End and a female end. The Male end screws into the Master Cylinder, and the female end accepts your first length of brake hose. The Solenoids are equipped with two wires that are not function specific. One grounds to the trailer tongue. The second wire runs towards the front of your tongue and connects to the Blue wire as mentioned above in your 5 Flat harness. Disc Brakes require this device in order to reverse your trailer without the brakes locking up. When your truck is put in reverse, a signal is transmitted from your reverse lights through a wire that is hooked to your trucks plug, which continues to your trailers plug, through the blue wire and to the solenoid, which stops the flow of brake fluid. If your connection or ground is bad, this device will not work properly and your brakes will lock up in reverse.


4. Kodiak Disc Brake Kits- When the Hydraulic Fluid flows through the brake lines and into the caliper, the pressure is exerted into the caliper causes the piston to push the inner brake pad towards the rotor, which causes the braking action and slows the trailer.  Each Kodiak Kit includes the Rotor or Hub/Rotor Combo, Caliper Brackets, and Calipers. We offer both the Slip On Style with or without Hubs and the Integral Style (hub/rotor combo). Here is Kodiaks Disc Brake Installation Manual that also includes useful troubleshooting tips regarding your trailers disc brake system.

Helpful Tips

Rinsing your Brake System - When thinking about maintaining your disc brake system and "rinsing it off", most people will generally say, "off course, I rinse it off every time I get back from the boat ramp." We know how corrosive saltwater is to boat trailers. It seems to be an endless battle to protect parts from rust. However, with Kodiak protective coatings and with proper action taken, you can double the life of your trailers disc brakes. For example, rinsing of your trailer when you get back to the house at the end of the day only rinses off the water that was just soaked on the brakes when you loaded the boat. What about the saltwater they were dipped in that morning that was allowed to coat and absorb all day long? 
If your local ramp as a freshwater wash down, use it! Rinse down your trailers calipers and inside the bell of the wheel to get your rotor rinsed off. Rinse of your Surge Actuator as well, as this is a commonly overlooked component. If you do not have access to a freshwater hose for easy wash down, maybe pick up a Pest Sprayer from your local hardware store. Fill it with freshwater and after launching your boat in the morning use it to rinse of your Brake Components and any other area you desire. You are spending money for the highest quality disc brake system for your trailer, so taking the extra steps to protect it will ensure a longer life for your investment. 

Will Kodiak Brakes Work on My Axle?- Since you are deciding on switching to Kodiak Brand disc brakes, you may be wondering if the Kodiak Brakes are compatible on your current trailer axle. First of all, your trailer axle must have a Brake Flange on each side of the Axle. 
-For 3,500lb Axles (5 Lug Hubs), the standard is a 4 Hole Brake Flange. Standard 4 Hole Flanges measure 2 3/4" Center to Center Hole Horizontally and Vertically.
-For 5,200lb Axles( 6 Lug Hubs), the standard is a 5 Hole Flange. Standard 5 Hole Flanges measure 2 1/8" inches from Bolt hole to Bolt Hole. 
The Presence of these standard flanges ensures your ability to mount Kodiak Disc Brakes to your trailers Axle.  
-The Standard Spindle on 3,500lb trailer axles is the #84 Spindle which measures 1 3/8" x 1 1/16" and has a spindle seal surface of 1.72"
The Bearing Numbers would be 68149 (1 3/8") x 44649 (1 1/16") with a Grease seal measuring 1.72" Inner Diameter.
-The Standard Spindle on 5,200lb trailer axles is the #42 Spindle which measures 1 3/4" x 1 1/4" and has a spindle seal surface of either 2 1/4" or 2 1/8"
The Bearing Numbers would be 25580 (1 3/4") x 15123 (1 1/4") with a Grease seal measuring 2 1/4" or 2 1/8" Inner Diameter.
If these measurements match your current Axle and Bearing set up your will be able to successfully use Kodiak Brakes on your trailer axle. 

Switching from one brand of trailer disc brake to Kodiak Disc Brakes - If you previously had another brand of disc brake on your trailer and you are wondering if Kodiaks will now fit on your brake flange and work on your axle. 
-For 3,500lb Axles with 4 Hole Brake Flange. You can Replace the following brands with a complete Kodiak Disc Brake Kit
Titan, Tie Down Engineering, and Unique Functional Products. These are the Major Brands of Disc Brakes that you would see other the Kodiaks. 
-For 5,200lb Axles with 5 Hole Brake Flange. You can Replace the following brands with a complete Kodiak Disc Brake Kit
Titan, Tie Down Engineering, and Unique Functional Products. These are the Major Brands of Disc Brakes that you would see other the Kodiaks.
**UFP (Unique Functional Products) also makes a 5,200lb Axle that uses a larger 4 Hole Brake Flange, the brakes would also use this Flange in most cases. If you have this Brake Flange on your Axle, then the UFP Brakes will be the only brakes that will mount on your axle. You would need to get a new axle with the standard 5 Hole Flange in order to use the higher quality Kodiak Brake. 

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