Tow Brake, LLC.

3606 Highway 62/412 S.

Hardy, Arkansas 72542

Sales:

sales@towbrake.com

Support: technical@towbrake.com

The Cost of Good Trailer Brakes

 By Greg Bess and Mike Butler

August 19, 2004

More and more folks in the trailer industry are experiencing the wonders of better braking through the use of Hydraulic Disc Brakes and a Hydraulic Actuator.  As a manufacturer and installer of these, we are always getting the question “How can the extra cost be justified.”  Our staff will answer, “What extra cost?”   Sure there are costs associated with getting the technology initially, but if you view the whole picture over at least the first 5 to 6 years of the life of a trailer, the costs are really savings.  Let us explain.

Take as test subjects two tandem axle trailers with 8,000lb axles.  It could be a travel trailer, a horse trailer/camper combo, or car hauler/toy hauler.  On one, let’s order it with basic drum trailer brakes; on the other let’s order it with hydraulic disc brakes and a hydraulic actuator.  What is our initial cost?  Chart A provides some reasonable costs associated with outfitting each trailer.

We have factored in the cost of a hydraulic actuator on the Hydraulic Disc/Caliper trailer.  As of this writing, actuator costs are in the range of $500 to $1,000 dollars depending on the model you use.  These are the prices MOR/ryde uses for new Disc Brakes and an HD3000 actuator from Tow Brake International Ltd. 

We have to admit at this point just seeing these numbers the decision is simple, but we have not left the showroom yet.  What costs are associated with the use of the trailer?  To understand this, let’s look at the brake system maintenance cycle with both trailers.  Chart B shows a typical maintenance scenario for each trailer over the course of 6 years.  Here we assume you will need to service your brakes every two years following initial delivery.  Most axle manufactures suggest service at least every 12,000 miles.  We have customers that report servicing their electric brakes every year.  Your numbers may vary due to usage and load, but let’s see what our numbers provide.   

Using realistic numbers from present day service records, Chart B shows that the cost to maintain Drum Brakes is greater by a factor of over 4 to 1.  With these figures you pay back the initial cost for using hydraulics with savings in maintenance cost with the first brake overhaul.  The hydraulic system then starts paying for itself with each additional service call.  Maintenance costs will vary with region, but, as we are seeing in the automotive industry, drum brake maintenance is more costly than disc. 

We know some of you will say, “you are too high on parts”, “I can go three years instead of 2”, or “I do the labor myself”.  For your situation, you are correct.  Plug your own numbers into the chart and see what you get.  Most of our customers report savings in 3 years or less.

We sum our understanding of costs in Chart C.

This chart dramatically answers the initial question “How can the extra costs be justified?”  The answer is: there is no extra cost.  Substantial savings are realized when the cost is viewed over the life of the trailer.   Although there is no data yet to support the claim, some folks are reporting better resale value with hydraulic brakes installed.  Our graph of Chart D my help in visualizing this trend.

Industry studies have shown time and again that better braking can be achieved with hydraulic disc brakes.  Their performance over time is superior to electric brakes.  As of this writing, several manufacturers are offering hydraulic actuators to power this braking trend.   What should you look for when specifying hydraulic components? 

First, we suggest that you find a trailer manufacturer that understands the numbers we’ve shown above and, more importantly, preaches the safety and quality of better braking systems.  You’ll know them when you meet them because they understand that by spending more up front both of you will save in the long run.  You will save in cost and with quality.  He will save by not seeing you as often and by knowing you will be smiling when you feel the performance difference of hydraulics. 

Second, make sure you recover your investment.   Choose the components in your braking system that will last as long as possible.  As shown in this example, adding more cost in maintenance years lessens your payback.  Some actuators on the market, while providing great performance initially, are just not capable of spanning all the years you will need it.  Find a vendor that uses high quality parts and proven technology with the longest warranty. 

When you have chosen your trailer with better braking, take some time to understand how to use and take care of it.  As with a new car, you need to understand the feel of the system and your hydraulic components will need to be checked and maintained.  The manufacturer’s manual will provide service intervals and details for servicing or see a qualified hydraulic systems dealer.  Watch how you set your vehicle controller for control of the trailer brakes.  The towing vehicle and trailer should brake together as a team.  With hydraulic brakes, it is possible to have the trailer brake for both (yes, electric brake folks, it’s quite possible!).  More aggressive braking at trailer in respect to the towing vehicle will cause excessive wear on your trailer brakes, trailer tires, and could over stress couplings.  Our customers tell us “we forgot the trailer is back there” when they get the settings adjusted correctly.

If you are a trailer owner looking at upgrading to hydraulic brakes, the results above will also work in your favor; however you may be looking at a longer payback cycle.  The payback depends on how you view the initial cost of the brakes you have and the added cost of the new brakes.  In our new trailer example the system pays for itself in the first maintenance cycle.  Since you have to bare the burden of the entire cost of initial set of brakes and now the retrofit, payback may be later.   You probably have a better feel for the numbers to use in the calculations.   Chances are good however, you are already knowledgeable of the data we are showing.  You have lived it!  You are looking at the safety and performance.

As our favorite song writer Jimmy Buffet nicely states in one of his tunes, “answers are the easy part, questions raise the doubt.”  The issue is who is asking the question of cost.  If it is the trailer manufacturer, they may not be seeing the total cost picture.  The trailer owner will see this over time but may not experience it until later sometime after leaving the dealer showroom.  That is why we are providing this information.  A colleague of ours in the industry once told a friend of his pondering the brake cost issue as an option on a new trailer, “Either insist on getting the trailer with hydraulic brakes or ask the dealer to provide a 10 year warranty on the brake system.  See which one the dealer picks.”    More and more manufacturers and dealers are becoming aware of the “savings and quality of good hydraulic braking”.  We hope this bit of information helps you look at a bigger picture.

Enjoy better braking!

Tow Brake, LLC. 3606 Highway 62/412 South Hardy, Arkansas 72542

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