Dexter Axle K71-499-00 Electric Brake Assembly Instruction Manual

Introduction

This manual provides comprehensive instructions for the Dexter Axle K71-499-00 electric brake assembly. It is essential to read and understand all instructions before attempting installation, operation, or maintenance. Proper installation and maintenance are crucial for safe and efficient trailer braking performance. If you are unsure about any step, consult a qualified technician.

The Dexter Axle K71-499-00 is a 12 1/4 x 3 3/8 inch electric brake assembly, specifically designed for the left-hand side of a trailer axle. It includes all necessary brake shoes and lining for a complete replacement or new installation.

Product Overview

The Dexter Axle K71-499-00 electric brake assembly is a critical component for trailer braking systems. It is designed for durability and reliable performance. Key features include:

• Model: K71-499-00
• Size: 12 1/4 inches diameter by 3 3/8 inches width
• Type: Electric Brake Assembly
• Side: Left Hand (Driver's Side)
• Components: Includes brake shoes and lining

This assembly is engineered to provide effective stopping power when properly integrated with a compatible trailer brake controller.

Image: Dexter Axle K71-499-00 Electric Brake Assembly. This image shows the complete brake assembly, including the backing plate, brake shoes, and magnet assembly, ready for installation on a trailer axle.

Setup and Installation

Safety First: Always ensure the trailer is securely supported on jack stands and the wheels are chocked before beginning any work. Disconnect the trailer from the tow vehicle and battery. Wear appropriate personal protective equipment, including safety glasses and gloves.

Required Tools and Materials:

• Socket/Wrench Set
• Torque Wrench
• Wire Strippers/Crimpers
• Electrical Connectors (butt connectors, heat shrink)
• Grease Gun and High-Temperature Grease
• Brake Cleaner

Installation Steps:

1. Remove Old Assembly (if applicable): Carefully disconnect the existing brake wiring. Unbolt the old brake assembly from the axle flange.
2. Inspect Axle Flange: Clean the axle flange thoroughly. Ensure it is free of rust, debris, or damage.
3. Mount New Assembly: Align the new K71-499-00 brake assembly with the axle flange. Secure it using the appropriate bolts, washers, and nuts. Torque bolts to manufacturer specifications (refer to your axle manual for specific torque values).
4. Wire Connection: Connect the brake assembly wires to the trailer's existing brake wiring. Typically, one wire is for ground and the other for the brake signal. Ensure connections are secure, weather-tight, and properly insulated (e.g., using heat shrink connectors).
5. Install Hub and Drum: Clean and inspect the wheel hub and brake drum. Install new bearings and seals if necessary. Pack bearings with high-temperature grease. Carefully slide the hub and drum assembly onto the spindle.
6. Adjust Bearings: Adjust wheel bearings according to axle manufacturer specifications.
7. Initial Brake Adjustment: After installing the drum, adjust the brake shoes. Locate the star wheel adjuster through the access hole in the backing plate. Using a brake spoon or screwdriver, turn the star wheel until a slight drag is felt when rotating the wheel. Then back off the adjuster slightly until the wheel rotates freely with minimal drag.
8. Final Checks: Re-check all connections and fasteners. Ensure the wheel rotates freely without excessive play.

It is highly recommended to have a qualified technician perform or verify the installation to ensure proper function and safety.

Operating Instructions

The Dexter Axle K71-499-00 electric brake assembly operates in conjunction with a trailer brake controller installed in the tow vehicle. The brake controller sends an electrical signal to the brake magnets, which then engage the brake shoes against the drum, providing braking force.

Before Each Trip:

• Test Brake Controller: Ensure your tow vehicle's brake controller is properly connected and functioning. Most controllers have a manual override lever and a display to indicate brake activity.
• Check Brake Function: With the trailer connected, apply the manual override on your brake controller. You should hear the brake magnets engage and feel resistance when attempting to pull the trailer forward.
• Adjust Gain: Adjust the gain setting on your brake controller according to the manufacturer's instructions and your trailer's load. The goal is smooth, proportional braking without locking up the trailer wheels.

During Operation:

• Smooth Braking: Avoid sudden or harsh braking whenever possible.
• Monitor Performance: Pay attention to how the trailer brakes feel. Any unusual noises, vibrations, or reduced braking effectiveness should be investigated immediately.

Maintenance

Regular maintenance is essential for the longevity and safe operation of your Dexter Axle K71-499-00 brake assembly. Perform these checks at least annually or every 12,000 miles, whichever comes first.

Maintenance Schedule:

1. Wheel Bearing Inspection and Lubrication: Remove the wheel, hub, and drum. Inspect wheel bearings for wear or damage. Clean and repack bearings with high-temperature wheel bearing grease. Replace seals as needed.
2. Brake Shoe and Drum Inspection: Inspect brake shoes for wear, cracks, or contamination (oil/grease). Replace shoes if worn down to 1/16 inch or less of lining material. Inspect the brake drum for scoring, cracks, or excessive wear.
3. Brake Magnet Inspection: Check the brake magnet for wear. The magnet face should be smooth. If the magnet is grooved or worn unevenly, it should be replaced. Ensure the magnet wires are securely attached and not frayed.
4. Brake Adjustment: Re-adjust the brakes after inspection and reassembly. Follow the initial brake adjustment procedure described in the Setup section.
5. Wiring Inspection: Check all brake wiring for chafing, corrosion, or loose connections. Repair or replace any damaged wiring.
6. Backing Plate Inspection: Inspect the backing plate for any signs of damage or bending. Ensure all mounting bolts are tight.

Troubleshooting

This section addresses common issues you might encounter with your electric brake assembly.

Common Issues and Solutions:

• No Trailer Brakes:
  • Check tow vehicle's brake controller for power and error codes.
  • Inspect trailer wiring harness and connections for damage or corrosion.
  • Verify ground connection for the brake assembly.
  • Test brake magnets for continuity and proper resistance.
• Weak or Inconsistent Braking:
  • Adjust brake controller gain setting.
  • Check brake shoe adjustment; they may be too loose.
  • Inspect brake shoes for wear or contamination.
  • Check brake magnets for wear or damage.
  • Ensure proper voltage is reaching the brake magnets.
• Uneven Braking (one side brakes harder):
  • Check brake shoe adjustment on both sides.
  • Inspect brake shoes and drums for wear or contamination on the affected side.
  • Verify wiring connections to ensure consistent power to both brake assemblies.
  • Check for damaged or faulty brake magnets.
• Brakes Dragging or Overheating:
  • Brake shoes may be adjusted too tightly.
  • Check for seized wheel bearings.
  • Ensure the brake controller is not sending a constant signal to the brakes.

If troubleshooting steps do not resolve the issue, consult a professional trailer service center.

Specifications

Warranty Information

Specific warranty terms and conditions for the Dexter Axle K71-499-00 brake assembly are provided by the manufacturer, Dexter Axle. Please refer to the warranty documentation included with your purchase or visit the official Dexter Axle website for detailed information regarding coverage, duration, and claims procedures. Keep your proof of purchase for warranty purposes.

Support

For technical assistance, replacement parts, or further inquiries regarding the Dexter Axle K71-499-00 brake assembly, please contact Dexter Axle customer support directly. Contact information can typically be found on the manufacturer's official website or on the product packaging.

When contacting support, please have your product model number (K71-499-00) and purchase information readily available to expedite assistance.