Zackdadams
Jet Boat Junkie
- Messages
- 293
- Reaction score
- 443
- Points
- 147
- Location
- MS Gulf Coast
- Boat Make
- Yamaha
- Year
- 2021
- Boat Model
- FSH Sport
- Boat Length
- 25
EDITING IN PROGRESS 
Incoming tutorial for replacing brake calipers, surge actuator, rotors, and more.
Now a disclaimer: I am not a mechanic.
There are most definitely steps that could be improved in this tutorial!
Tools Needed:
Part 1: The Calipers, Rotors, & Leaf Springs
I live on the Gulf Coast, exclusively using my boat in salt or brackish water.
Each time, I rinse the brakes down with water, afterwards I use salt away, and follow it up with fluid film.
However, saltwater is a beast, so it's time to do some maintenance, replace my calipers, and refurbish or replace anything else needed on the trailer.
You will want to buy lots of Water Displacement Formula #40 for this install!
Step 1: Disassembly & Decisions
Remove your wheels and tires.
Once they are off, you should be able to get a good look at the state of your brakes, calipers, rotors, leaf springs, & brake lines.
In my circumstance, i'm replacing the calipers, and going to refurbish everything else.
Start by removing the brake lines screwed into the calipers, with a small box wrench.
Wrap the ends of the brake lines with paper towels and painters tape.
Note: The starboard side calipers have 2x brake lines each.
We will be reusing this 2-port valve off the old caliper.
Step 2: Remove the Calipers
You will use a 3/8 allen wrench socket on the back side of the caliper.
They are in very difficult locations, so you will probably want to buy a swivel knuckle for your socket set.
I ended up having to use a piece of pipe on the end of my socket wrench to initially break the nut free.
Once both allen bolts are removed, you may have to use a dead blow mallet to persuade the caliper off the rotor.
Step 3: Hub & Rotor Disassembly
You should now have these parts in front of you.
Step 4: Refurbish or Replace the Rotors
My rotors weren't that bad, so I decided to keep them.
Your situation might be different.
Take the rotors to a professional shop.
They can turn the rotors, giving them new life.
Alternatively, buy new rotors.
(Don't do what I did: Watch YouTube.
Use a grinder with a flap disk to clean them up.)
Step 5: The Leaf Springs
At this point, take stock of the condition of your Leaf Springs.
Mine are still decent, so I opted to Sand Blast, Prime, and Paint.
Tape up your spindle and brake lines.
Use a wire brush to scrape off the rust, and follow up with a light sand blasting.
I purchased this light duty model from Harbor Freight.
Afterwards, spray Acid Etching Primer, followed by Black Rustoleum.
Step 6: Grease, Grease, & More Grease
Clean all your parts using a combination of paper towels, Parts Cleaner, & rubber gloves.
Once everything is cleaned, apply a generous amount of marine grease to the spindle, bearings, and interior of hub.
I'm using Lucas Marine Grease which is designed for boat trailer bearings.
Afterwards reassemble the hub.
Finally, use a grease gun on the zerk fitting to fully the grease the hub.
Here's a great video explanation of greasing and reassembly:
Step 7: Attach the New Calipers
The new calipers are Dexter DB-35 Aluminum.
(2) Left Side #42015L
(2) Right Side #42015R
Caliper Installation Steps
Here is the finished product, before & after.
Note: The Brake lines are strapped to the trailer frame with metal clips.
Mine had pretty much rusted away, so I removed them.
I used large zip ties each foot to re-secure the lines.
Afterwards, I sanded, primed, and painted the axel black.
Finally, take this opportunity to slap on some new wheels and tires!
Incoming tutorial for replacing brake calipers, surge actuator, rotors, and more.
Now a disclaimer: I am not a mechanic.
There are most definitely steps that could be improved in this tutorial!
Tools Needed:
- Large Floor Jack
- Impact Wrench w/ Sockets
- SAE Socket Set
- Channel Locks
- C-Clamp
- Flat Head Screwdriver
- Needle Nose Vice Grips
- Stubby Allen Impact Sockets
Part 1: The Calipers, Rotors, & Leaf Springs
I live on the Gulf Coast, exclusively using my boat in salt or brackish water.
Each time, I rinse the brakes down with water, afterwards I use salt away, and follow it up with fluid film.
However, saltwater is a beast, so it's time to do some maintenance, replace my calipers, and refurbish or replace anything else needed on the trailer.
You will want to buy lots of Water Displacement Formula #40 for this install!
Step 1: Disassembly & Decisions
Remove your wheels and tires.
Once they are off, you should be able to get a good look at the state of your brakes, calipers, rotors, leaf springs, & brake lines.
In my circumstance, i'm replacing the calipers, and going to refurbish everything else.
Start by removing the brake lines screwed into the calipers, with a small box wrench.
Wrap the ends of the brake lines with paper towels and painters tape.
Note: The starboard side calipers have 2x brake lines each.
We will be reusing this 2-port valve off the old caliper.
Step 2: Remove the Calipers
You will use a 3/8 allen wrench socket on the back side of the caliper.
They are in very difficult locations, so you will probably want to buy a swivel knuckle for your socket set.
I ended up having to use a piece of pipe on the end of my socket wrench to initially break the nut free.
Once both allen bolts are removed, you may have to use a dead blow mallet to persuade the caliper off the rotor.
Step 3: Hub & Rotor Disassembly
- Remove Dust Cap
- Spin the rotor while gently tapping the central hub with a rubber mallet.
- Remove the cotter pin.
- Remove the nut.
- Pull the rotor towards you, releasing the bearing & washer.
- Catch these with a paper towel, as they are covered in grease.
- Use a flat head screwdriver to release the clips inside the grease hub.
- Separate the spring, clips, & zerk cap.
- Remove the rotors.
You should now have these parts in front of you.
Step 4: Refurbish or Replace the Rotors
My rotors weren't that bad, so I decided to keep them.
Your situation might be different.
Take the rotors to a professional shop.
They can turn the rotors, giving them new life.
Alternatively, buy new rotors.
(Don't do what I did: Watch YouTube.
Use a grinder with a flap disk to clean them up.)
Step 5: The Leaf Springs
At this point, take stock of the condition of your Leaf Springs.
Mine are still decent, so I opted to Sand Blast, Prime, and Paint.
Tape up your spindle and brake lines.
Use a wire brush to scrape off the rust, and follow up with a light sand blasting.
I purchased this light duty model from Harbor Freight.
Afterwards, spray Acid Etching Primer, followed by Black Rustoleum.
Step 6: Grease, Grease, & More Grease
Clean all your parts using a combination of paper towels, Parts Cleaner, & rubber gloves.
Once everything is cleaned, apply a generous amount of marine grease to the spindle, bearings, and interior of hub.
I'm using Lucas Marine Grease which is designed for boat trailer bearings.
Afterwards reassemble the hub.
Finally, use a grease gun on the zerk fitting to fully the grease the hub.
Here's a great video explanation of greasing and reassembly:
Step 7: Attach the New Calipers
The new calipers are Dexter DB-35 Aluminum.
(2) Left Side #42015L
(2) Right Side #42015R
Caliper Installation Steps
- Replace & install the 2-port valve on the starboard side calipers.
- Use a C-clamp to compress the central piston.
- Apply very small amount of caliper grease to brake pad ears.
- Clean Rotors with Parts Cleaner.
- Install New Calipers over the Rotor.
- Install New Bolts
- Bleed Brakes after Surge Actuator installation. (explained in next section)
Here is the finished product, before & after.
Note: The Brake lines are strapped to the trailer frame with metal clips.
Mine had pretty much rusted away, so I removed them.
I used large zip ties each foot to re-secure the lines.
Afterwards, I sanded, primed, and painted the axel black.
Finally, take this opportunity to slap on some new wheels and tires!
Last edited:
