When you’re towing a caravan, you’re not just pulling extra weight—you’re changing how your vehicle accelerates, corners and, most importantly, stops. That’s where electric brakes come into play. While they’re often overlooked by first-time travellers, they’re one of the most critical safety systems in your entire setup.
Understanding how these brakes work isn’t just for mechanics or grey nomads—it’s essential knowledge for anyone towing a van across Australia. Whether you’re planning to upgrade your tow rig, checking out caravans in Heatherbrae or simply want to feel more in control behind the wheel, it pays to know exactly what’s going on when you hit the brake pedal.
Let’s pull back the curtain on electric caravan brakes: what they are, how they work and why you absolutely need them working at their best.
What Are Electric Brakes and Why Do Caravans Use Them?
Electric brakes are a braking system designed to slow or stop a caravan independently of the tow vehicle. Unlike hydraulic or mechanical brakes, which rely on physical linkages or fluid pressure, electric brakes use an electrical signal from the towing vehicle to activate braking mechanisms inside the caravan’s wheels.
They’re the standard for most Australian caravans over 750 kg for a few good reasons:
- They provide proportional braking force based on how hard you press the pedal
- They allow for manual adjustment using a brake controller
- They offer better control when descending hills or in emergency situations
Without electric brakes, your tow vehicle would have to do all the stopping—which not only increases stopping distance, but puts massive strain on your car’s brake system.
The Core Components of a Caravan Electric Brake System
A caravan’s electric brake system is surprisingly straightforward once you know the main parts involved. These components work together to apply braking force safely and smoothly.
Here’s what makes up a typical setup:
- Brake magnets: Located inside the drum, these receive electrical current and create the force needed to engage the brakes.
- Drum brakes: Standard on most vans, these contain the shoes and friction material that press against the drum when the magnet activates.
- Wiring harness: Delivers power from the vehicle’s controller to the brake magnets.
- Brake controller: Mounted in the tow vehicle’s cabin, it regulates how much power is sent to the brakes based on driver input.
- Breakaway system: A backup safety feature that automatically applies full braking power if the van detaches from the car.
When all these parts are set up correctly and maintained, your caravan brakes will activate in sync with your car’s brakes, giving you smooth, predictable stopping power.
How Electric Brakes Actually Engage When You Brake
So what happens when you step on the brake pedal in your car? Here’s how the sequence unfolds in a van with electric brakes:
- The brake controller in your car senses the deceleration and sends an electric signal back to the caravan.
- That signal flows through the wiring harness and energises the electromagnetic brake magnets inside the drums.
- The magnets are drawn toward the spinning brake drum surface, dragging the attached brake shoes into contact with the drum.
- This contact creates friction, which slows the rotation of the wheels—and by extension, the entire caravan.
The stronger you press your brake pedal, the more current is sent to the magnets. This gives you proportional braking, meaning the van slows down at the same rate as your vehicle. It’s a smooth system that prevents jerky stops and reduces stress on both vehicles.
What Does the Brake Controller Do?
The brake controller is the brains of the operation. Mounted near the dash of your tow vehicle, it determines how much braking power to send to the caravan—and when.
There are two main types of controllers:
- Time-delayed: These send a preset amount of power after a short delay, regardless of how hard you’re braking.
- Proportional: These detect the rate at which your car is slowing and adjust the trailer brakes to match in real time.
Proportional systems are far superior for safety and comfort, especially on long descents or in wet weather. They’re more expensive but well worth the upgrade if you’re doing regular towing.
Most controllers also come with manual override levers. This lets you apply the caravan brakes independently of your car, which is handy for preventing sway or controlling speed on long hills.
When and Why You Need a Breakaway System
Electric brake setups on caravans over 2,000 kg are legally required to have a breakaway system—and for good reason. If the caravan detaches from the tow vehicle, this system triggers the brakes automatically to bring it to a stop.
Here’s how it works:
- A cable connects the caravan to the tow vehicle.
- If the connection is broken (due to a hitch failure or disconnection), the cable pulls a pin out of the breakaway switch.
- This activates the onboard battery system, which applies full braking force to all wheels until the van stops.
It’s a small device, but a critical one. It turns a potentially catastrophic accident into a controllable situation.
Breakaway systems need regular testing, especially before long trips. A failing battery or damaged pin can render the whole thing useless—something you definitely don’t want to discover on the highway.
Electric Brakes vs Mechanical Override: What’s the Difference?
Some smaller trailers and campervans use mechanical override brakes instead of electric ones. These work by using the trailer’s momentum to compress a spring in the coupling, which in turn pulls brake cables.
Here’s how they compare:
- Mechanical override is cheaper and simpler, often found on trailers under 2 tonnes.
- Electric brakes provide better control, adjustability and stopping power, especially on longer or heavier vans.
- Mechanical systems can’t be manually adjusted from the car.
- Electric brakes allow for real-time tuning and independent braking control.
For serious touring and full-size caravans, electric brakes are the standard for a reason. They simply offer better safety and more refined handling across varied terrain.
Common Problems with Electric Brakes (And How To Fix Them)
Even a good system needs attention from time to time. If your caravan’s brakes feel weak, noisy or erratic, there may be an issue in one of several areas.
Here are the most common problems:
- Brake magnets worn out: If they’re not pulling properly, they can’t apply pressure to the drums.
- Wiring faults: Corrosion or loose connections can cut power to the magnets.
- Brake shoes glazed or contaminated: Oil or rust reduces friction and braking power.
- Controller calibration off: If the system is too aggressive or too soft, it needs tuning.
Regular maintenance and inspections will keep your setup running smoothly. Many travellers do a full check of their brakes before any major trip, including testing the controller and inspecting wiring for wear.
Real-World Example: Towing Confidence on Long Descents
Let’s say you’re descending Mount Ousley, fully loaded with a 2.5-tonne van behind your ute. Without electric brakes, you’d be riding your vehicle brakes hard, risking overheating and fade.
But with a properly set up electric brake system, your controller senses the descent and engages the caravan brakes in tandem. If you need more control, you can nudge the manual override to apply trailer braking without touching your vehicle brakes—keeping everything smooth and steady.
It’s not just safer—it’s a calmer, more confident towing experience that makes the journey far less stressful.
Are Electric Brakes a Legal Requirement in Australia?
Yes, in most cases they are. The Australian Design Rules (ADRs) specify that trailers and caravans must meet the following requirements:
- Under 750 kg: No brakes required.
- 751–2,000 kg: Brakes required on at least one axle. Electric or mechanical allowed.
- Over 2,000 kg: Electric brakes required on all axles, with a functional breakaway system.
If your setup doesn’t comply, you’re not only risking safety—you’re technically unregistered. That can lead to fines, insurance voidance or worse in the event of an accident.
Before buying a van or hitting the road, always check that your brake system matches your caravan’s weight and current ADRs. It’s your responsibility as the driver.
FAQs
Do I need a brake controller to tow a caravan?
Yes, if your caravan uses electric brakes, a brake controller is essential. Without one, the caravan brakes won’t receive the electrical signal they need to activate.
Brake controllers give you proportional control, helping the caravan slow down in sync with your car. Without that, all the braking is left to your vehicle—which is unsafe and often illegal.
Controllers can be hardwired into the dash or connected via plug-and-play units depending on your vehicle. Either way, it’s non-negotiable if your van is fitted with electric brakes. Always test it before towing to make sure it’s calibrated correctly.
Can I tow a caravan without electric brakes?
Only if your caravan weighs under 750 kg—and most don’t. Australian law requires brakes on trailers over this weight. Between 750 and 2,000 kg, you can use mechanical override brakes, but electric brakes are more common.
If your van has electric brakes installed, they must be operational. Towing without them, even if the van is within legal limits, puts unnecessary strain on your vehicle and increases the chance of accidents.
So while it’s technically possible in some cases, it’s not advisable. Electric brakes provide smoother, safer towing and help meet legal and insurance requirements.
How often should I service caravan electric brakes?
As a rule of thumb, you should inspect your electric brakes every 10,000 km or before any extended trip. Key things to check include:
- Brake magnet wear
- Shoe thickness and condition
- Drum surface for scoring or rust
- Wiring integrity and plug condition
If you’ve been towing in wet, muddy or dusty conditions, it’s wise to check them even sooner. Don’t forget to test the brake controller and override function too.
Regular servicing not only keeps you safe—it also extends the life of your gear and helps avoid breakdowns on the road.
Why are my caravan brakes locking up?
If your electric brakes are locking up, it’s likely a calibration issue with the controller. Too much power is being sent to the brakes, causing them to grab instead of engage smoothly.
Other causes could include:
- Faulty brake magnets
- Grease or oil on the brake shoes
- Incorrect shoe adjustment inside the drum
Try reducing the brake controller gain setting and test again. If the problem continues, it’s best to have the system inspected by a professional. Brake lockups not only make driving harder—they can cause flat spots on your tyres and dangerous handling.
Do electric brakes work in reverse?
Yes, but not always automatically. Some caravan electric brakes are fitted with a reverse function bypass, allowing the van to be moved without engaging the brakes. Others may lock up unless the controller detects reverse gear and disables output.
Modern systems and controllers often have reverse detection built in. If your van locks up when reversing, you may need to upgrade your brake controller or fit a diode bypass into the wiring.
Before hitting the road—or reversing into a tight site—check how your setup handles reverse. It’s one of those small things that makes a big difference when it counts.
Built for Safety: Why Electric Brakes Are a Towing Essential
Electric brakes are more than just a tick-the-box requirement—they’re one of the smartest and most impactful safety features in any towing setup. Whether you’re hauling a weekend camper or a full-size van for a lap of the country, they give you the stopping power, stability and control you need.
Don’t treat them as “set and forget.” Understand how they work, test them regularly and adjust as needed to suit your load and driving conditions.
Start your journey with confidence — visit 7th Street Caravans or give our team a call on 02 4012 6009 for friendly, local advice.