I purchased what I think has to be one of the best brake controllers I have seen but have not yet towed with it. It is called a Brake Smart controller out of Dallas. They use a micro switch in brake line to determine brake line pressure. Seems like it would be a very progressive even braking. The display has also sorts of info from Date/time/voltage/amps applied to trailer/PSI of brake line. Looks like I may be getting a new truck before I tow with this truck and was looking for someone that has used one before I pay another 400 for a brake controller. (I have to leave the brake controller on the old truck when I sell it or install a new one which I don't see as practical)
-
TDR Magazine subscribers receive more than the magazine! You also gain additional forum privileges!
Details here: TDR Privileges
Subscribe to TDR Magazine here: https://www.tdr-online.com/
brake controller
- Thread starter Eric_77
- Start Date
Attention: TDR Forum Junkies To the point: Click this link and check out the Front Page News story(ies) where we are tracking the introduction of the 2025 Ram HD trucks.
Thanks, TDR Staff
I am supprised that any company would sell something where you have to modify the brake circuit by installing a pressure sensor into it. Not that I think its wrong, but the liablilty would be very high in todays world.
I am very happy with my Jordan Ultma (runs around $130 bucks). It applys brakes by sensing the position of the brake pedel with a cable.
I did have a problem with My Jordan. I sent it back to Jordan and they fixed it with no problems. While it was out for repair I had to run a trip with my old Kelsey Hayes enertia controler. I don't see how I was able to stand that old controler after using the Jordan.
I am very happy with my Jordan Ultma (runs around $130 bucks). It applys brakes by sensing the position of the brake pedel with a cable.
I did have a problem with My Jordan. I sent it back to Jordan and they fixed it with no problems. While it was out for repair I had to run a trip with my old Kelsey Hayes enertia controler. I don't see how I was able to stand that old controler after using the Jordan.
Like TowPro, I'm amazed that anyone is seriously trying to sell these hydraulic proportional controllers again (they were available back in the 60's and 70's). The vehicle manufacturers all warn against any device that taps into the hydraulic brake lines. Further, if you have 4 wheel anti-lock brakes, I would think the pulsating brake line pressures when the anti-lock was engaged would drive a hydraulic brake controller nuts!
I use the Jordan - IMHO, it's as good as you can get without tapping into the truck's brake circuits.
Rusty
I use the Jordan - IMHO, it's as good as you can get without tapping into the truck's brake circuits.
Rusty
Well this is what they tell me it moves a very minute amount of fluid less than . 01 ml so it has no effect on vehicle braking performance and rather than a tap it has a T that is threaded into M/C then brake line to that. I have 4wheel ABS and it goes before ABS controller haven't seen it do anything weird on the display when I hit the ABS (granted I didn't have a trailer hooked up), I wonder if the electric brakes coule cycle with thetruck ABS I. E. ABS for the trailer? Is there ABS available for electric brakes? I know the air brakes on Semi's tractor and trailer all are required to have ABS now.
By the way the 400 was installed price.
By the way the 400 was installed price.
Eric,
Who manufactures and who sells the Brake Smart you described? I'd like to buy the T fitting and maybe even look at your truck or another truck to see where the T is tapped into the line. Can you describe the location or send me a diagram?
I have corresponded with an engineer at Kelsey-Hayes (now Hayes Lemmerz) regarding use of the old-fashioned hydraulic-electric K-H controller on late model trucks. I installed one on my previous truck, a 1994 Ford F250HD with rear ABS and it worked perfectly. It provided perfect modulated trailer braking with no adjustment, readjustment, or cables to tinker with.
K-H literature for the old controllers states that the controller displaces less than 0. 02 cubic inches or less than 0. 3 cubic centimeters of fluid. This was well within specs provided by the manufacturers before they became silent on the issue.
I have not been able to find any mention of approval or prohibition of use by Ford or Dodge but as recently as about three years ago, Chevrolet truck brochures authorized tapping the brake line and installing a hydraulic-electric controller as long as it displaced less than 0. 02 cubic inches of master cylinder fluid. I don't know if Chevy truck brochures even mention it any longer.
Just before I bought my Dodge I called the Dodge customer service line and asked about installing the brake controller.
After I pressed hard and talked to several people I finally reached a guy who emphatically stated that neither he or Dodge would authorize such installation but he admitted that he knew of no reason why it wouldn't work.
It was lawyers and the potential of lawsuits that removed the old-fashioned hydraulic-electric brake controllers from the market, not technology.
I bet this one stirs up a controversy.
Harvey
Who manufactures and who sells the Brake Smart you described? I'd like to buy the T fitting and maybe even look at your truck or another truck to see where the T is tapped into the line. Can you describe the location or send me a diagram?
I have corresponded with an engineer at Kelsey-Hayes (now Hayes Lemmerz) regarding use of the old-fashioned hydraulic-electric K-H controller on late model trucks. I installed one on my previous truck, a 1994 Ford F250HD with rear ABS and it worked perfectly. It provided perfect modulated trailer braking with no adjustment, readjustment, or cables to tinker with.
K-H literature for the old controllers states that the controller displaces less than 0. 02 cubic inches or less than 0. 3 cubic centimeters of fluid. This was well within specs provided by the manufacturers before they became silent on the issue.
I have not been able to find any mention of approval or prohibition of use by Ford or Dodge but as recently as about three years ago, Chevrolet truck brochures authorized tapping the brake line and installing a hydraulic-electric controller as long as it displaced less than 0. 02 cubic inches of master cylinder fluid. I don't know if Chevy truck brochures even mention it any longer.
Just before I bought my Dodge I called the Dodge customer service line and asked about installing the brake controller.
After I pressed hard and talked to several people I finally reached a guy who emphatically stated that neither he or Dodge would authorize such installation but he admitted that he knew of no reason why it wouldn't work.
It was lawyers and the potential of lawsuits that removed the old-fashioned hydraulic-electric brake controllers from the market, not technology.
I bet this one stirs up a controversy.
Harvey
No controversy here. The best brake controller would sense brake system hydraulic pressure and translate that into an output signal to the trailer brakes. It's just that, with the manufacturers and lawyers out there, I'm amazed that anyone would market a controller today that required physical intervention into the brake hydraulic system - it's opening a real Pandora's box of issues.
Rusty
Rusty
Rusty,
To clarify, I don't think Hayse-Lemmerz actually manufactures the old-fashioned hydraulic-electric controller any longer. Fear of liability killed demand several years ago.
I have two of them, one of which I bought new in the box off the shelf at a local RV dealer about three years ago. I used it for one year on my previous Ford before buying the Dodge.
If I can find the proper T fitting and advice on where to tap into the system I'll jump on the opportunity to use it again on my Dodge. I think the worst thing that could happen would be pulsating trailer brakes if I braked hard enough on a slippery road surface to cause the truck's ABS to kick in and pulse the truck brakes. My guess is that if the tap is next to the master cylinder and before the ABS circuitry the trailer brake controller wouldn't feel the truck's ABS braking. Even if it did, I don't know if that would be bad. If the truck's ABS was activated because the truck was skidding on a wet or slippery surface it might even be desirable to have the trailer do the same. I'm willing to install the brake controller and find out if an undesirable situation is created. I could test it and remove it if a problem existed.
Harvey
To clarify, I don't think Hayse-Lemmerz actually manufactures the old-fashioned hydraulic-electric controller any longer. Fear of liability killed demand several years ago.
I have two of them, one of which I bought new in the box off the shelf at a local RV dealer about three years ago. I used it for one year on my previous Ford before buying the Dodge.
If I can find the proper T fitting and advice on where to tap into the system I'll jump on the opportunity to use it again on my Dodge. I think the worst thing that could happen would be pulsating trailer brakes if I braked hard enough on a slippery road surface to cause the truck's ABS to kick in and pulse the truck brakes. My guess is that if the tap is next to the master cylinder and before the ABS circuitry the trailer brake controller wouldn't feel the truck's ABS braking. Even if it did, I don't know if that would be bad. If the truck's ABS was activated because the truck was skidding on a wet or slippery surface it might even be desirable to have the trailer do the same. I'm willing to install the brake controller and find out if an undesirable situation is created. I could test it and remove it if a problem existed.
Harvey
The BrakeSmart controller is made by Master Brake Systems in Dallas (www.masterbrake.com).
While everyone else in the trailer world is cowering in a corner passing off '50's technology, Master has had the courage and good sense to go forward and design and produce equipment that is sorely needed in today's heavy towing world (and I believe will be legally required at some time in the future).
The first product in this line was the Elecdraulic actuator (electric over hydraulic) that came out a few years ago with far more electronics than seemed necessary to run a screw-jack in proportion to the brake signal from the controller. I have used them since they were new (usually at 36k gross with a tridem on Kodiak discs behind my F-450 4x4 tractor), and I can tell you that the actuator is top drawer equipment (the Kodiak disc calipers... . another story).
I have waited for the BrakeSmart for a couple of years as the guys at Master have told me about its development. What it does is put a little pressure transducer (pizeo I believe) with next to no swept volume (swelling of a brake hose or line under pressure will be much more volume) to read the brake pressure you are trying to get on the tractor. An inertial unit has to pause while the pendulum takes a WAG on what you MIGHT have wanted for braking, if only the trailer brakes were in the game yet. A mechanical unit can make a more informed guess, but it is ultimately dependant upon adjusting for pedal position and can hardly be adjusted in a hurry. The BrakeSmart looks at the line, and immediately tells the brakes to apply to the level set on the controller proportional to the measured effort.
IF you have the matching Elecdraulic actuator, there is a matching transducer in the brake circuit of the trailer, so the brake proportioning adjustment on the controller merely has to give an output the calculates the ratio between the truck and trailer that you set in a fast push of the key(s). All with NO detectible delay!!!!! It is as close to driving an empty car that trailer brakes will ever get!
What else can it do? Well, to begin with, it will operate regular electric brakes, take a look at the number of axles, display the results to you, and give you an output to match the number of axles on the trailer. Got air suspension? The BrakeSmart will lower it for you to unload, and lock the brakes (if you have Master actuator) while you are at it. Got air jacks? It will run them too. Of course, it will communicate with any Master devices on the line back there and display error messages on the screen if something is wrong. It will even tell you what it is hooked to when you first plug in.
The truck ABS does not bother the controller, BUT, the actuator is designed for ABS in the trailer as soon as testing has been concluded. You can buy discs with tone rings now, and plug the ABS unit into one of the plugs on the acutator that seemed so surplus a few years back.
I do not work for Master, or sell anything for them. I operate a service business that tows all over North America, sometimes in a big panic and LOTS of it in the Rockies. This stuff is what I needed to downsize equipment out of class 8 air brake rigs and into medium trucks. I now have braking in these units far superior to what I have in our regular tractor-trailer units. I have used the BrakeSmart personally (along with Elecdraulic) for most of this year, and, guys, THIS is the future.
Pat
While everyone else in the trailer world is cowering in a corner passing off '50's technology, Master has had the courage and good sense to go forward and design and produce equipment that is sorely needed in today's heavy towing world (and I believe will be legally required at some time in the future).
The first product in this line was the Elecdraulic actuator (electric over hydraulic) that came out a few years ago with far more electronics than seemed necessary to run a screw-jack in proportion to the brake signal from the controller. I have used them since they were new (usually at 36k gross with a tridem on Kodiak discs behind my F-450 4x4 tractor), and I can tell you that the actuator is top drawer equipment (the Kodiak disc calipers... . another story).
I have waited for the BrakeSmart for a couple of years as the guys at Master have told me about its development. What it does is put a little pressure transducer (pizeo I believe) with next to no swept volume (swelling of a brake hose or line under pressure will be much more volume) to read the brake pressure you are trying to get on the tractor. An inertial unit has to pause while the pendulum takes a WAG on what you MIGHT have wanted for braking, if only the trailer brakes were in the game yet. A mechanical unit can make a more informed guess, but it is ultimately dependant upon adjusting for pedal position and can hardly be adjusted in a hurry. The BrakeSmart looks at the line, and immediately tells the brakes to apply to the level set on the controller proportional to the measured effort.
IF you have the matching Elecdraulic actuator, there is a matching transducer in the brake circuit of the trailer, so the brake proportioning adjustment on the controller merely has to give an output the calculates the ratio between the truck and trailer that you set in a fast push of the key(s). All with NO detectible delay!!!!! It is as close to driving an empty car that trailer brakes will ever get!
What else can it do? Well, to begin with, it will operate regular electric brakes, take a look at the number of axles, display the results to you, and give you an output to match the number of axles on the trailer. Got air suspension? The BrakeSmart will lower it for you to unload, and lock the brakes (if you have Master actuator) while you are at it. Got air jacks? It will run them too. Of course, it will communicate with any Master devices on the line back there and display error messages on the screen if something is wrong. It will even tell you what it is hooked to when you first plug in.
The truck ABS does not bother the controller, BUT, the actuator is designed for ABS in the trailer as soon as testing has been concluded. You can buy discs with tone rings now, and plug the ABS unit into one of the plugs on the acutator that seemed so surplus a few years back.
I do not work for Master, or sell anything for them. I operate a service business that tows all over North America, sometimes in a big panic and LOTS of it in the Rockies. This stuff is what I needed to downsize equipment out of class 8 air brake rigs and into medium trucks. I now have braking in these units far superior to what I have in our regular tractor-trailer units. I have used the BrakeSmart personally (along with Elecdraulic) for most of this year, and, guys, THIS is the future.
Pat
The way I read your information regarding the Brake Smart Controller, it can be used either as a stand alone with the existing electric trailer brakes or in conjunction with the Electro-hydraulic set up? I am primarily interested in the electric only, as that is what the trailer is running I pull, but I really like the idea of the hydraulic tie-in for more accurate braking.
SRehberg:
Yes, it will work just fine running regular electric brakes. The big thing is that the output is nearly instant and easily/quickly adjustable. If you do super-heavy electric braked loads, there is a boost feature available that will bump the voltage for an extra shot of braking.
You don't want to pull a trailer with hydraulic discs unless you are prepared to go home and change everything over. At least with a BrakeSmart in the tow vehicle, you could justify to your wife that you have the first few hundred in the deal so far, so it would only make sense the spend the next couple of thousand.
Pat
Yes, it will work just fine running regular electric brakes. The big thing is that the output is nearly instant and easily/quickly adjustable. If you do super-heavy electric braked loads, there is a boost feature available that will bump the voltage for an extra shot of braking.
You don't want to pull a trailer with hydraulic discs unless you are prepared to go home and change everything over. At least with a BrakeSmart in the tow vehicle, you could justify to your wife that you have the first few hundred in the deal so far, so it would only make sense the spend the next couple of thousand.
Pat
pdolan:
I'm interested in a BrakeSmart.
Did you buy your BrakeSmart controller and install it yourself? If so, where did you buy it and how difficult was installation?
If you purchased it installed, who sold and installed it for you?
Where do you recommend buying the BrakeSmart and who do you recommend for installation?
Does Master Brake sell direct to consumers or only to jobbers?
Any information or advice will be appreciated.
Harvey
I'm interested in a BrakeSmart.
Did you buy your BrakeSmart controller and install it yourself? If so, where did you buy it and how difficult was installation?
If you purchased it installed, who sold and installed it for you?
Where do you recommend buying the BrakeSmart and who do you recommend for installation?
Does Master Brake sell direct to consumers or only to jobbers?
Any information or advice will be appreciated.
Harvey
Thanks Pdolan for the info I thought it looked good.
I am going to get one installed on the 2003 next week. I decided to keep the 96 truck(which had brake smart installed) and sell the old 92.
HBarlow The T fitting is installed directly into the front master cylinder fitting then the brake line is attached to it. I don't have a digital camera or scanner so I cannot post images. I am not going to disassemble but I would say the thread for T appears to be 1/4 pipe.
I am going to get one installed on the 2003 next week. I decided to keep the 96 truck(which had brake smart installed) and sell the old 92.
HBarlow The T fitting is installed directly into the front master cylinder fitting then the brake line is attached to it. I don't have a digital camera or scanner so I cannot post images. I am not going to disassemble but I would say the thread for T appears to be 1/4 pipe.
Issue 128 – Digital Version
Digital Magazines
FREE!
TDR Test Drive - Digital Edition
Renew
Subscribe
Gift Subscriptions
Back Issues
Subscription Status
Address Change Form
Buyer's Guides
Ram Diagnostic Trouble Codes
The Perfect Collection
The Perfect Collection Vol. II
TSB Updates
Dodge/Cummins Historical Overview
Cameron Collection
What Makes Us Tick?
Product Showcase
Advertising
Turbo Diesel Register
Issue 128 – Digital Version
Digital Magazines
FREE!
TDR Test Drive - Digital Edition
Renew
Subscribe
Gift Subscriptions
Back Issues
Subscription Status
Address Change Form
Buyer's Guides
Ram Diagnostic Trouble Codes
The Perfect Collection
The Perfect Collection Vol. II
TSB Updates
Dodge/Cummins Historical Overview
Cameron Collection
What Makes Us Tick?
Product Showcase
Advertising
