How to Install an OzHitch Brake Cable Kit

The OzHitch Brake Cable Kit is designed to provide a reliable and secure connection between your trailer’s hand brake and the trailer’s braking system. With high-quality stainless steel components, this kit ensures smooth operation and long-lasting performance. This guide will walk you through the installation process to get your brake system set up and ready for use.

Important: Always wear appropriate personal protective equipment (PPE) such as gloves and safety glasses during installation. If you’re unsure about any part of the process or lack the necessary tools, it’s recommended to consult or hire a professional for the installation.

OzHitch Brake Cable Kit

What’s Included in the Kit:

  • 1 x 8m Stainless Steel Cable
  • 1 x Cable Adjuster
  • 2 x Cable Clamps

Tools You’ll Need:

  • Wire cutters (for cutting the cable to length)
  • Wrenches or spanners (for adjusting and securing components)
  • Safety gear (gloves and safety glasses)

Step-by-Step Installation Guide

Step 1: Determine Cable Route

Before installing the brake cable, determine the optimal path for the cable to run from the hand brake lever to the trailer’s brake mechanism. Ensure the cable path is smooth and free of sharp edges or obstructions that could cause friction or wear.

  • Pro Tip: Route the cable along the trailer’s frame and avoid any tight bends to prevent strain on the cable.

Step 2: Measure and Cut the Cable

Using the 8-meter stainless steel cable provided, measure the required length for your trailer setup.

  1. Route the cable from the hand brake to the brake drum or brake lever on the trailer.
  2. Once you’ve determined the correct length, use wire cutters to trim the excess cable. Be sure to leave some extra length to allow for adjustment and tensioning later.

Step 3: Attach the Cable to 1 of the Brake Mechanisms

Next, secure one end of the cable to the trailer’s brake mechanism.

  1. Feed the cable through the brake lever or drum.
  2. Once in place, use one of the provided cable clamps to securely fasten the cable end.
  3. Tighten the clamp using a spanner or a wrench to ensure it holds the cable securely in place.

Step 4: Install the Cable Adjuster

The cable adjuster allows you to adjust the tension of the brake cable, ensuring smooth operation and proper braking force.

  1. Install the cable adjuster to the handbrake lever at the coupling.
  2. Thread the cable through the adjuster and ensure it’s positioned to allow for easy adjustment of the tension.
  3. Once installed, you’ll be able to fine-tune the brake tension as needed by turning the adjuster.

Step 5: Attach the Cable to the other Brake Mechanism

Now it’s time to attach the other end of the cable to the remaining brake mechanism.

  1. Feed the cable through the hand brake mechanism.
  2. Use the second cable clamp to secure the cable at the hand brake connection point.
  3. Ensure the cable is taut but not overly tight, leaving room for slight adjustments as needed.

Step 6: Adjust Cable Tension

With the cable fully installed, it’s time to adjust the tension to ensure the brakes engage and release smoothly.

  1. Use the cable adjuster to fine-tune the tension on the brake cable.
  2. Test the hand brake by pulling the lever and confirming that the brakes engage and hold the trailer in place.
  3. Adjust as necessary to achieve the right balance between tension and smooth operation.

Final Check

After installation, double-check the following:

  • The cable tension is properly adjusted and the brakes engage smoothly.
  • The cable clamps are securely fastened at both ends of the cable.
  • The cable is routed properly and secured to the frame to prevent movement or damage during towing.

Maintenance Tips

  • Regularly inspect the cable and adjust the tension as needed to maintain optimal braking performance.
  • Check the cable for any signs of wear or fraying, especially after off-road trips or long periods of use.
  • Re-grease or lubricate moving parts where necessary to keep the system running smoothly.

Need Assistance? Contact Us!

If you have any questions or need further assistance, feel free to call us on (08) 8260 2277 or Contact Us here. We’re here to help ensure your OzHitch coupling is always performing at its best.

For more installation resources and tips, visit our Resources Page.

OzHitch: Built for the journey. Ready for every adventure.