Your caravan handbrake plays quite an important role when it comes to you and your van’s safety, but the handbrake cable can deteriorate. But thankfully the expert team at the RV Repair Centre showed us how to replace it.
The handbrake mechanism is the first line of defence in preventing your caravan from rolling away when parked. (We need to mention that chocking wheels is a necessary second line of defence as handbrakes are notoriously ineffective.) The caravan handbrake cable is the link between the hand operated lever mounted on the A-frame and the lever mounted on the drum brake assembly. The brake cable can become corroded or frayed giving the potential for it to fail and release the brake mechanism.
The RV Repair Centre showed us how to replace the handbrake cable. We had the luxury of performing the task on a hoist. The average DIYer is likely to perform this task on the ground. It is critical that all steps are taken to ensure the van does not roll while working on it to prevent the risk of serious injury or death. This includes working on flat ground and using wheel chocks.
The process of replacing the handbrake cable is quite simple. However, it is vital that the new brake cable is adjusted to the correct tension. If it is too loose it will not activate the brake. If it is too tight it will cause the brakes to activate in transit even when the handbrake lever is released. This is because the brake cable becomes tighter when the axle moves upward in its range of suspension travel.
STEP 1 — Find the cable clamp securing the handbrake cable to the brake lever
|
STEP 2 — Loosen the nuts on the cable clamp
|
 STEP 3 — Remove the end of the brake cable from the cable clamp |
 STEP 4 — Pull the brake cable through the brake lever |
 STEP 5 — Remove the brake cable from the brake lever |
 STEP 6 — Remove the cable clamp from the brake cable |
 STEP 7 — Repeat the above steps on the other side of the van to remove the brake cable from the brake lever |
 STEP 8 — Pull the brake cable through the chassis loops |
 STEP 9 — Remove the brake cable from the chassis loop |
 STEP 10 — Repeat removing the brake cable from the chassis loops on the other side of the van |
 STEP 11 — Pull the brake cable through the brake cable adjuster |
 STEP 12 — Remove the brake cable from the brake cable adjuster |
 STEP 13 — Remove the nut and bolt securing the brake cable adjuster |
 STEP 14 — Remove the brake cable adjuster |
 STEP 15 — Fit the new brake cable adjuster |
 STEP 16 — Do not overtighten the bolt so that the mounting bracket can still pivot on the lever |
STEP 17 — Feed the new brake cable through a chassis loop closest to the brakes
|
 STEP 18 — Continue to feed the brake cable through all the chassis loops working towards the A-frame |
 STEP 19 — Feed the brake cable through the brake cable adjuster |
 STEP 20 — Feed the brake cable through all of the chassis loops on the opposite side working back towards the brakes |
 STEP 21 — Feed the brake cable through the new cable clamp |
 STEP 22 — Feed the brake cable through the brake lever |
 STEP 23 — Loop the brake cable and make it short enough that it will not rub against the tyre wall |
 STEP 24 — Feed the brake cable end through the cable clamp |
 STEP 25 — Tighten the cable clamp |
 STEP 26 — Repeat the process of feeding the brake cable through the cable clamp on the opposite side |
 STEP 27 — Loop the brake cable near the brake lever to determine if the brake cable needs shortening |
 STEP 28 — Make a mark where to cut it if required |
 STEP 29 — Trim the wire at the mark with suitable cutters |
 STEP 30 — Repeat the process of feeding the cable through the brake lever, looping it and feeding it into the cable clamp. Only finger tighten the cable clamp at this point |
 STEP 31 — Loosen the lock nuts at either end of the brake cable adjuster |
 STEP 32 — Rotate the wheel to adjust cable tension. Moving the brake cable adjuster pulley closer to the handbrake mechanism increases tension and vice versa |
 STEP 33 — The tension is correct when the handbrake lever can be pulled firmly to about 75 per cent of the ratchet range |
 STEP 34 — A cable that is too tight when the handbrake is released can cause the brakes to inadvertently apply when the axle moves through its suspension travel up and to the rear |
 STEP 35 — Tighten the lock nuts at both ends of the brake cable adjuster |
 STEP 36 — Tighten the second brake cable clamp |
 STEP 37 — Wrap tape around both exposed cable ends |
If in doubt, consult a professional
Improper maintenance can lead to injury, death or property damage. Maintenance work of this nature should only be undertaken by people with suitable competence. The information provided is general in nature, not comprehensive and should only be taken as a guide. Individual discretion must be exercised and persons undertaking described tasks do so completely at their own risk. Publishers and creators of this content accept no responsibility for loss or damage.
Thanks to Andrew Phillips and the team from the RV Repair Centre, 120 Canterbury Road, Bayswater North Vic 3151, P: 03 9761 4189
THE NEXT STEP
If you want to learn the latest caravan news, find the most innovative new caravans and camping gear or get inspired to plan your next adventure to some of Australia's best getaway destinations, subscribe to our weekly newsletter. We promise to send you only the best content.
Related articles:
DIY: How to replace a caravan breakaway switch
DIY: Installing a Cuddy composting toilet in your van
DIY: How to replace a caravan handbrake cable