Frayed Brake Wire on 2021 400 BD!!

manyman297 · July 2021

Long story short, I was under the camper today to adjust the drum brakes as one side seemed to be hotter than the other side (and had some burning brake smell) after our past weekend trip. I figured the brakes could use an adjustment. Easy task.

While under the camper today I noticed the brake wire had so much slack in it that it was rubbing against the tire and is nearly split!

Some of you may have seen my post about the quality control issues we've been having with out trailer:
https://tab-rv.vanillacommunity.com/discussion/13753/400-amazing-trailer-terrible-qc#latest

The issues before seem minor now compared to this one. I'm sure I can splice the wire back together somehow but how do you leave a wire hanging with so much slack? Common sense would tell you it's going to rub against the tire.

I'm posting this as a caution for anybody who cares to go and check the slack on your electric brake cables and secure them so they aren't dangling. I've got an email into to NuCamp to see what they have to say.

Just when we were starting to turn a corner and beginning to enjoy this trailer, I find this.

Image: https://us.v-cdn.net/5021717/uploads/editor/fs/w80ahsnchyqz.jpeg

fstop32 · July 2021

I feel your pain @manyman297.

Sharon_is_SAM · July 2021

Ouch! Glad you caught that. Good reminder to check the brake wires.

manyman297 · July 2021

Quick update. NuCamp reached out and was apologetic about the mishap. I was able to make the repair myself which involved cutting both wires (to shorten the overall length) and using waterproof heat shrink butt connectors and then heat shrinking the entire wire assembly again in a heat shrink tube.

Nucamp did a good job on the heat shrink tubing but I was surprised they didn't use waterproof butt connectors. The black tubing isn't necessarily waterproof so using waterproof connectors is good practice.

But I'd definitely check your rig and make sure there isn't a ton of slack in your brake wire assembly. I can't imagine we were the only ones with this issue.

manyman297 · July 2021

One additional update. Prior to fixing this brake wire I had to dial up my brake controller to 10 or so to get stopping power. After fixing it I've had to reduce the power down to 2.5 (I was chirping my trailer tires at 3.5). So clearly I was losing power due to the frayed wire.

A new issue I'm now working out is why the passenger brake drum gets hotter than the drivers. Stay tuned.

William_Keever · July 2021

manyman297, how do you know one side is getting hotter than the other? Are you using some type of thermal imaging device or are you touching the brake drum with your hand?

manyman297 · July 2021

@William_Keever Thermal imaging device. Those infrared ones. I took some baseline temps driving a certain distance. I then backed off the star wheel a few clicks and did the same route noting the temps. Definitely much less heat on the passenger side but still maybe a 20% difference after downhill braking. Backing off the brake controller solved the super high temps I was getting (160 driver vs. 227 passenger at one point) but still seeing higher temps on the right side. No dragging though which is reflected in highway driving (minimal braking). Maybe a 5-10 degree difference between the two.

Interestingly my Tacoma has the same issue but just not as extreme. Maybe a 10% temp difference after some spirited braking.

William_Keever · July 2021

@manyman297 Which thermal device do you use? I might want to get one.

manyman297 · July 2021

William_Keever said:

@manyman297 Which thermal device do you use? I might want to get one.

Mine is the same brand as this but older model I think:

Limited-time deal: Etekcity Infrared Thermometer 749 (Not for Human) Temperature Gun Non-Contact Digital Laser IR Thermometer-58℉~ 716℉ (-50℃ ~ 380℃), Standard Size, Black-Yellow https://www.amazon.com/dp/B07QZ1849H/ref=cm_sw_r_cp_api_glt_fabc_dl_A2H6C6N9MPSKXNP0QCKT?_encoding=UTF8&psc=1

jcrystal · July 2021

Glad I saw your posting. I checked my 2021 TAB320S, with about 400 miles on it, and same issue on passenger side. Wires were bared, but not broken, so I covered with electrical tape and secured them closer to the outlet, hope that is all that is necessary.

manyman297 · July 2021

Yeah, it was just dumb luck I was under there checking why one brake drum was hotter than the other. Pretty frustrated by a lot of the little things we're finding wrong on the trailer but trying to stay optimistic.

—edited to remove unnecessary and incorrect disparaging remark about nüCamp’s quality control —Verna, T@B Forum Administrator

manyman297 · July 2021

@Verna that comment may be disparaging but might not be incorrect.

Maxcamp · February 2022

We had precisely the same problem on Feb. 2021 TAB 320S. Passenger side electric brake wire factory installation was faulty. The teeny plastic split pin in harness intended to hold slack in place fails on bumps and wind. The wire sheathing ground off against tyre and nearly half the copper. Amazingly still had electrical connection but soent two miserable afternoons in very cold altitudes splicing in sound cable. As designed there us no sound way to keep cable in place!
This is a MANUFACTURER DEFECT and lifesafety issue.
Nucamp told us we are not warranteed, having bought a thirty day old secondhand trailer from original buyer.

Maxcamp · February 2022

We too sre pretty frustrated at the many things poorly installed. Tray with sheetmetal screws.
Lift insert in spare tyre has diameter 6 mils greater than hub opening and forces spare cockeyed until laboriously removed, ground with angle grindrr, and reinstalled requiring $73 cable swedging tool. Useless rear aluminum rack misfabricated in factory but installed anyway with foot bolted to trailer at 42 degree angle rather than aligned. Door trim with failung doublestick tape. Unresolved NO PROPANE AT ALTITUDE, WELL KNOWN. Unresolved Alde thermostat reading way off tens if degrees
Trailer jack does not clear tailgates of Tacoma, Ranger, other half ton trucks... Does no one tow with these?

[Deleted User] · February 2022

This also happened on my 2019 400. I got a brake failure warning on my brake controller.

donmontalvo · April 13

Just saw the same issue on my new 2024 320S, while taking pics of the torsion suspension, noticed the electric brake wire on the passenger side was rubbing against the inner rim, and burned through the red wire cover and through a few wire strands.

(someone mentioned one brake drum being hotter than the other; that can happen if the first drum is getting proper power, but the other is getting power through a wire that’s missing a few strands.)

Easy fix. Splice the wire, use solder seal for the connection, and adhesive shrink wrap so the fix is sealed. Then use silicone caulk to seal the grommeted hole the wire comes out of (water, dust, critters can get in), then use a self tapping screw and a 1/4” wire clamp to secure the wire to the frame.

donmontalvo · April 13

[Deleted User] said:

This also happened on my 2019 400. I got a brake failure warning on my brake controller.

My Redarc brake controller had errors. Jeep side tested out fine. I replaced the camper cable plug, then the entire umbilical. Kept getting errors but brakes kept working. Fast forward to today, see my last post…camper electric brake wire was damaged. Easy fix though.

donmontalvo · April 13

— edited to remove unnecessary and incorrect disparaging remark about nüCamp’s quality control —Verna, T@B Forum Administrator

$#!+ happens on products all the time. I am a fan of helping the company by pointing out issues, fixing, and providing illustrated before and after summaries.

it is a much more polite and productive approach than venting at the company…though every once in a while I am guilty of violating Wheaton’s Law…

¯\_(ツ)_/¯

manyman297 · April 13

I think the concern for me (I was the OP) is that here we are almost four years later and we’re still seeing this issue pop up. Nucamp needs to either fix it (easy enough to do) or come to the realization that their QC processes aren’t where they should be. This isn’t a trivial issue.

B0atguy · April 14

Yep, happened to us on our 2024 400 . Was coming home from the "2nd" shakedown trip and the brake controller warning popped up with a fault detected . Pulled over and found the brake wire was rubbed through and the wires frayed due to contact with the lugs on the side of the boondock tire . Have read quite a few instances of this still happening with even newer NuCamp trailers. You figure they would put a little more attention on this as it is not an uncommon failure now . I even mentioned it to NuCamp when discussing some "other" warranty work needed . They didnt seem to concerned about it

.

donmontalvo · April 15

Fixed.

Bill&Suze · April 15

@manyman297, thanks for posting this alert. I took a look last summer and both sides were secure. Just looked again and the loops coming off the axle to the back of the wheel are still quite secure. Although those look to be well installed, last summer I had to add quite a few more ties to the brake wire suspended between wheels. There were maybe three ties and the wire dangled low to the ground at several locations along its length.

donmontalvo · April 16

Bill&Suze said:

@manyman297, thanks for posting this alert. I took a look last summer and both sides were secure. Just looked again and the loops coming off the axle to the back of the wheel are still quite secure. Although those look to be well installed, last summer I had to add quite a few more ties to the brake wire suspended between wheels. There were maybe three ties and the wire dangledee low to the ground at several locations along its length.

In my case the wire was zip tied to the axle but where it came out of the gusseted hole it had excessive slack. If it were secured there this wouldn’t have happened. Hence the self tapping screw and wire clamp it my image.

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Frayed Brake Wire on 2021 400 BD!!

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