2003–2007 Dodge Trucks equipped with 5.9L Cummins

APPLICATION:
APPLICATION:
2003–2007 Dodge Trucks equipped
5.9L and
Cummins
and Manual
Fixedwith
Orifice
PRXB™
ExhaustTransmissions
Brakes For
2006 and 2007 Dodge Trucks equipped with 5.9L Cummins and Automatic Transmissions
2003 and Newer Dodge Trucks with 3.5” and 4” Exhaust
VEHICLES WITH AN EXISTING AIR COMPRESSOR AND AIR TANK
Dodge 2003 And Newer
Getting Started
Thank you and congratulations on your purchase of a Pacbrake Direct Mount® exhaust retarder.
Do not install the kits listed below on 2003 model year Dodge trucks built up to June 27th 2005 with
automatic transmissions without a transmission controller. Pacbrake has kits for these vehicles that
include an automatic transmission controller.
Contact Pacbrake’s Customer Service @ 800.663.0096 for more information.
Pacbrake kit information and applications covered in this manual:
C44031 Pacbrake kit is a PRXB design for 2003 model year and newer Dodge trucks built up to January
4th 2004 with a Cummins 5.9L and manual shift transmission only.
C44037 Pacbrake kit is a PRXB design for Dodge trucks built after January 5th, 2004 and newer with
Cummins 5.9L diesel engines and a manual shift transmission. This kit also fits on Dodge trucks built after
June 27th, 2005 with Cummins 5.9L 610 ft-lbs of torque and automatic transmissions, transmission
controller is not required on trucks built after June 27th, 2005.
Pacbrake PRXB exhaust brakes require a minimum of 100PSI to fully close the butterfly valve, ensure your
pressure switch will maintain pressure above 100PSI.
Before starting the installation, please read the entire installation manual carefully. Check that your
PACBRAKE kit contains all the necessary parts. Pacbrake offers three optional accessories to enhance
your exhaust brake system that you may want to consider before starting the installation (see page 2).
1
Kit Contents
1 - Exhaust brake housing
1 - Dash harness
1 - Dash switch and plate
1 - Nylon airline 12 ft
8 - Tie straps
1 - Solenoid valve
1 - Engine harness
1 - Sub group solenoid mounting fasteners
1 - 90° fitting
2 - Tee fittings
3 - Straight fittings
1 - Tire fill kit
I N S TA L L AT I O N M A N U A L - L 5 8 9 2
PG. 1
Dodge 2003 And Newer
2
Optional Accessories
SWITCH-PAC GEAR SHIFT LEVER SWITCH
Part Number C18042
(for manual transmissions only)
An optional gear shifter switch is available for
manual transmission vehicles through Pacbrake
distribution system. Pacbrake part number C18042
for shifter diameter of 5/8".
MECHANICAL THROTTLE SWITCH GROUPS
Pacbrake offers mechanical throttle switch groups
to speed up the activation of the exhaust brake.
Part # C14037
2003 M/Y trucks with manual transmission
Part # C20135
2004 M/Y trucks with manual transmission
OPTIONAL CLUTCH SWITCH INSTALLATION KIT
Part Number C20097
(for manual transmissions only)
Provides brake disengagement during clutching.
Locate the two capscrews at the clutch lever. Remove the screw closest to the rear of the vehicle.
Install the Pacbrake switch on this capscrew as
shown. Tighten the capscrew. Adjust the switch
on the bracket so when the clutch is fully released
the clutch arm contacts the switch arm causing the
switch to click. Check the adjustment by moving the
clutch pedal. The switch should click in the freeplay movement of the clutch pedal, if not readjust.
Cut the white wire at the clutch switch, using the 2
push-on terminals supplied, crimp and connect to
the terminals on either terminal of the clutch switch.
I N S TA L L AT I O N M A N U A L - L 5 8 9 2
PG. 2
Dodge 2003 And Newer
Dash Switch Installation
3
Consult with the owner or operator of the vehicle for
their preference of dash switch location. The location shown in the photo is our recommendation for
a vehicle equipped with an automatic transmission.
Vehicles with manual transmissions, we recommend an optional shift lever mounted on/off switch
(C18042).
Once the switch location has been chosen, if a
dash switch is being installed, drill a 1/2" hole to
accommodate the toggle switch. Connect the white
wire to the top terminal and the black wire to the
bottom terminal. Connect the other end to a good
chassis ground. The white wire is connected later.
If installing a shift lever mounted on/off switch, follow the instructions provided within the C18042 kit.
Exhaust Brake Installation
4
INSTALLER OPTION (not mandatory)
Some installers remove the front wheels and
8 screws which secure the wheelhouse splash
shields. Doing this allows for easier access to the
exhaust elbow and the engine ECU on the drivers side of the vehicle. To remove the wheelhouse
splash shield completely, the ABS cable will need
to be disconnected from the splash shield.
Caution: If removing the front wheels for easier
access, make sure the vehicle is supported
properly.
5
&ENDER
2AIL
&ENDER
3CREWS
7HEELHOUSE
3PLASH
3HIELD
REMOVE FACTORY ELBOW
At the turbocharger locate the 2 “V” clamps fastening the exhaust elbow to the turbo and header
pipe. To prevent damage to the threads when
removing, apply a drop of oil as close to the nut as
possible, then remove both. Save both “V” clamps
for reuse. The factory elbow is indexed with two roll
pins. These pins should remain in the elbow and if
not, they MUST be removed from the turbo outlet
flange. These are for alignment of the elbow at the
truck assembly plant and are not required. Inspect
the sealing face of the turbo for carbon or other imperfections. If necessary, clean or repair to assure
a good seal will be made as no gaskets are used.
I N S TA L L AT I O N M A N U A L - L 5 8 9 2
PG. 3
Dodge 2003 And Newer
CAUTION: If installing a PRXB Exhaust Brake,
use care. When handling the brake assembly
be sure not to damage the regulator spring and
lever arm.
6
With the original turbocharger to elbow “V” clamp
placed loosely over the turbocharger outlet, insert
the Pacbrake housing into the exhaust system and
rotate the housing until the turbo flange and the
exhaust brake’s pressure flange are parallel. Install
the turbo clamp loosely first and rotate the
Pacbrake until the outlet flange aligns with the
header pipe. Once proper alignment is achieved
torque the turbo side clamp to 75 in-lbs (8.5 N•m).
Now loosely install the outlet side clamp and then
torque the outlet clamp to 100 in-lbs (11.3 N•m).
7
Solenoid Installation
Choose a location to mount the solenoid valve. It
should be mounted in a clean, dry area between
the air tank and the exhaust brake with the exhaust
port pointing down. Using the fasteners provided,
secure the solenoid to the vehicle.
8
Using the fittings and nylon airline provided, source
supply air from the tank, connect to solenoid port
mark “IN”. Connect the solenoid port marked “CYL”
to the air cylinder on the exhaust brake. Secure the
airline with the tie-straps provided.
Note: a quick connect air chuck is provided in the
accessory kit to connect the curly hose to the air
source. Also provided is a tee fitting to supply air
to the quick connect air chuck, install the tee fitting
either at the air tank or the solenoid port marked
“IN”. Install the air chuck in a clean dry area accessible to the operator.
I N S TA L L AT I O N M A N U A L - L 5 8 9 2
PG. 4
Dodge 2003 And Newer
9
Using the eye terminal provided, connect one of the
two solenoid wires to a good chassis ground. The
remaining solenoid wire connects yellow wire of the
main harness installed in step 10.
Wiring Harness Installation
10
Using the self tapping screw provided, secure the
relay receptacle to the inner fender on the drivers
side of the vehicle. Connect the yellow wire of the
Pacbrake harness to the remaining solenoid wire.
Locating an Ignition Power Source
11
2003 Model Year Vehicles:
12
2004 and 2005 Model Year Vehicles:
13
2006 and Newer Model Year Vehicles:
Locate the 14 pin connector on the passenger
side firewall. Pin 13 will be a dark blue wire which
should be a 12 volt positive ignition power source.
Using the T-Tap provided, connect the 10 amp red
fused link to the ignition power source.
Locate the two 24 pin connectors on the driver’s
side of the firewall. One connector is grey and the
other is black. In the black connector, pin B4 will be
a pink wire with a grey tracer. This wire should be
a 12 volt positive ignition power source. Using the
T-Tap provided, connect the 10 amp red fused link
to the ignition power source.
Locate the TIMP Module in front of the drivers’ side
battery. Release the lock tabs on the side of the
TIMP. This will allow the TIMP to be removed as
an assembly. Under the unit, locate connector “G”.
Cavity 14 will be a grey wire with pink tracer. This
wire should be a 12 volt positive ignition power.
Using the T-Tap provided, connect the 10 amp red
fused link to the ignition power source.
I N S TA L L AT I O N M A N U A L - L 5 8 9 2
PG. 6
Dodge 2003 And Newer
14
Route the black wire with the special ECM pin of
the harness to the engine’s ECM (drivers side of
the engine) if you are installing an ECM By-pass
system. (See note below).
The Engine Control Module (ECM) is bolted to the
left side of the engine below the intake manifold.
At the engine ECM, locate the two connectors. The
front connector is a 60 pin and the rear is a 50 pin.
Note: If installing the ECM bypass system, now
would be a convenient time to install. Follow the
instructions provided with that kit.
15
+%9
%NGINE#ONTROL-ODULE%#-
7AY#ONNECTOR
7AY#ONNECTOR
From inside the cab, locate the grommet in the
floor. Make a small hole in the grommet for the
white wire only. Insert the end with the special ECM
pin into the hole.
Note: If installing the optional clutch switch PN#
C20097, now would be a convenient time to install.
Follow the instructions provided with that kit.
16
Recover this wire and route it to the engine ECM.
At the 50 pin (rear) connector, locate pin #39.
Remove the sealing plug. Be careful not to push
it in.
Once the sealing plug is removed, insert the white
wire with the special ECM “PIN” into cavity #39.
Push in until seated. Gently pull on the wire to
ensure the pin is locked in place.
17
At the 50 pin (rear) connector, locate pin #42, and
remove the sealing plug. Be careful not to push it in.
Once the sealing plug is removed, insert the black
wire, with the special ECM pin, from the compressor
harness, into cavity #42. Push in until seated. Gently
pull on the wire to ensure the pin is locked in place.
1
11
21
31
41
5
6
10
1
5
6
10
20
51
11
30
KEY�
21
40
31
50
�
41
45
46
55
56
60
1.
Engine
Control
Module (ECM)�
Connector
A
2. 60-Way
Connector� Connector B
(60 Pin)
(50 Pin)
ECM
3. 50-WayEngine
Connector
20
30
40
50
Pin numbers from back side of connector
Cont. Next Page...
I N S TA L L AT I O N M A N U A L - L 5 8 9 2
PG. 7
Dodge 2003 And Newer
Secure both ECM wires with the tie-straps provided
1
5
6
10
1
5
6
10
Note: If the sealing plug is in too 11
deep to remove, or you cannot 20
11
21
30
push the two ECM pins in far enough
to lock in place, use a
21
31
40
31
41
50
4mm hex wrench to remove the center
capscrew of the 50 pin
connector from the ECM. If it is necessary
to
41
45
46
55 remove
56the plug60
51
from the ECM, both the batteries must be disconnected first to
prevent damage to the ECM. Once the connector
is removed
Connector
A
Connector B
(50 Pin)
from the ECM, push the sealing plug out from (60
thePin)
ECM side with
Engine
ECM
a small probe. Install both pins into the correct cavities,
re-install
Pin numbers
from back side of connector
the 50 pin connector and tighten. Reconnect the batteries.
20
30
40
50
CAUTION!
The white wire goes into the ECM pin #39. This is a ground input and under no circumstances should
12 volts positive be applied to this circuit. Damage to the ECM will result.
18
19
Note: If the wheelhouse splash guards were removed, they may be reinstalled now by following the
procedure in reverse.
Check Operation
Start the vehicle and allow it to idle. Note: The compressor should pump to fill the air tank. Turn the Pacbrake
switch to the ON position, and the exhaust brake should activate. Slowly raise the engine’s RPM. The Pacbrake
should shut off above 900 RPM (if it was on at an idle). Late 2003 and newer vehicles will disable the exhaust
brake at idle when the coolant temperature is above 170° F. If the exhaust brake fails to activate, using a 12 volt
test light, connect one side of the test light to the positive battery terminal. Place the probe end on the relay
terminal 85 which connects to Pin 42 of the engine ECM. Increase engine RPM and release the throttle quickly.
The test light should illuminate when the engine is decelerating. Keep in mind the ECM has a slight delay
activating the exhaust brake. If the test light does not illuminate, check the Pacbrake white wire in Pin 39 and
Pacbrake black wire in Pin 42 of the engine ECM for a good connection. See note in Step 17. Road test the
vehicle and retorque the clamps after the first 100 miles of driving. It may be necessary to remove the Pin 50
connector from the ECM if the wires don’t lock in the connector.
I N S TA L L AT I O N M A N U A L - L 5 8 9 2
PG. 8
Dodge 2003 And Newer
Dodge Compressor Wiring - Vehicles not Using ECM Bypass
Vehicle has an existing air source
(C18042 Shown)
For manual shift
transmissions
Black
White
Optional
Clutch Switch
Quick
Connect
Chuck
Nylon Airline
Chassis
Ground
Nylon Airline
Pressure
Switch*
*Must not allow
less than100PSI
at any time for
proper exhaust
brake operation.
To Solenoid Port “IN”
To Pacbrake
Air Cylinder
CYL
Existing Air Tank
Black
Pacbrake
Solenoid
Connect to Pin #39
Connector
50 Pin Connector "B"
View shown is of harness
connector installed in ECM
Yellow
1
10
20
30
40
11
21
31
41
45
46
Red
Solenoid
Relay
87
50
Connect to Pin #42
10 Amp
Fuse
Pacbrake
Pressure Switch
C11578
Max 130PSI
Min 110PSI
Black
85
86
30
Red with White Trace
Ignition
Power
Source
I N S TA L L AT I O N M A N U A L - L 5 8 9 2
PG. 9
*Pacbrake exhaust brakes are protected by law U.S. patents 5,445,248. Patents pending. Pacbrake is a registered trademark of Pacbrake Company.
Other trademarks used herein are property of their respective holders.
Printed in Canada L5892.11.28.07
PROCEDURES
SUBJECT
LOCATING AN
IGNITION POWER
SOURCE
APPLICATION
2003 and Newer
Dodge Installation
Addendum
2003
2003 model year vehicles
Locate the 14 pin connector on the passengers side
firewall, pin 13 will be a dark blue wire which should
be a 12 volt positive ignition power source.
2004 and 2005 model year vehicle
Locate the two 24 pin connectors on the driver’s
side of the firewall. One connector is gray and the
other is black, in the black connector pin B4 will be a
PINK wire with GRAY tracer. This wire should be a 12
volt positive ignition power source.
2006 and Newer model year vehicles
Locate the TIMP Module in FRONT of the drivers’
side battery. Release the lock tabs on the side of
the TIMP, this will allow the TIMP to be removed as
an assembly. Under the unit, locate connector “G”
cavity 14 will be a GRAY wire with PINK tracer. This
2004 / 2005
wire should be a 12 volt positive ignition power.
NOTE: Check the circuit with a volt meter for ignition
power and 12 volts prior to attaching the “T” tap. Do not
separate the connector as a fault code will be logged into
the ECM. If you need to separate the connector, discon2006 & Newer
nect both battery leads. This will prevent the logging of a
fault code in the ECM. Using the Blue “T” tap supplied,
attach it to an ignition power source and then connect to
the fuse harness supplied.
L5655.10.12.06
A D DE N DUM
SUBJECT: Pyrometer Thermocouple Installation Warning
APPLICATION: Fixed Orifice and PRXB™ Exhaust Brakes
2003 and Newer Dodge Trucks with 3.5” and 4” Exhaust
*5.9 Liter Cummins Only
IMPORTANT NOTICE
Do not install a pyrometer thermocouple in the back pressure test port, damage to the
thermocouple will result.
Pyrometer Thermocouple Port
1/4” NPT
Back Pressure Test Port
1/8” NPT
L5675.12.04.06
Product
INFORMATION
SUBJECT:
PAGE 1 OF 1
May 2002
Caustic Prevention Decal
ATTENTION PACBRAKE EXHAUST BRAKE OWNER/INSTALLER...
Please apply the attached decal to the engine or engine area as a precautionary measure.
These instructions will help to ensure the brakes trouble free operation and continued service.
Pacbrake Service
L5132.030904
Product
INFORMATION
SUBJECT:
PAGE 1 OF 1
MARCH 8TH 2006
2006 Model Year Dodge Trucks with 48RE automatic transmissions
Dodge has made changes to the software within the engine and transmission computers. These changes do
not allow the exhaust brake to be activated until the torque converter lock-up clutch is fully applied. When the
exhaust brake is activated the new software is designed to downshift the transmission from 4th to 3rd gear when
conditions allow The exhaust brake will disengage during downshifting as the torque converter drops out of lockup, it will not be re-applied until lock-up is achieved.
Downshifting from 4th to 3rd gear is accomplished by depressing the “Tow/Haul” button, a 3rd to 2nd gear downshift is accomplished by moving the shift lever to 2nd. Downshifts will not occur until the RPM is low enough
to prevent engine over-speed. Fixed orifice exhaust brakes require downshifting to provide high engine RPM to
enhance performance. The Pacbrake PRXB does not require the same level of downshifting due to backpressure
regulation.
Note: The new software and transmission design do not provide effective retarding in first gear.
Contact Pacbrake Service at 1 800 663 0096
L5588.080306
Pacbrake 2003 & Newer Dodge Exhaust Brake
Limited Warranty
PACBRAKE 2003 & NEWER DODGE EXHAUST
BRAKES LIMITED WARRANTY
This Pacbrake exhaust brake warranty applies to the 2003
and newer Dodge Diesel with a turbo mount exhaust brake.
Pacbrake Limited Warranty applies to the original purchaser
when on the engine of first installation. This warranty is for
Pacbrake exhaust brakes delivered after January 01, 2004.
The Warranty is non-transferable to next vehicle
owner or another engine.
The Pacbrake exhaust brake is a product of Pacbrake Company
and is warranted to be free of defects in material, workmanship
and operation under normal use and service for the warranty
coverage period set forth below. There are no representations
or warranties, which extend beyond the terms hereof.
THERE ARE NO OTHER WARRANTIES, EXPRESSED OR
IMPLIED, INCLUDING NO WARRANTY OF MERCHANTABILITY
AND NO WARRANTY OF FITNESS FOR A PARTICULAR
PURPOSE.
PRODUCT WARRANTED:
2003 and newer Dodge Diesel equipped with a Pacbrake turbo
mount exhaust brake.
WARRANTY COVERAGE
Exhaust Brake Warranty Coverage Period:
•Exhaust Brake Assembly - three years/100,000 miles,
whichever shall occur first.
Related Pacbrake attaching/control parts:
•Auxiliary air supply (compressor), pneumatic components,
controller, solenoid valve, harnesses, and switches 1 year / unlimited miles.
Exhaust Brake Replacement
Parts Coverage Period:
•Replacement parts - 180 days (unlimited mileage) or the
balance of the remaining warranty, whichever is longer.
Pacbrake replacement parts installed after expiration of the
original warranty shall be covered for a period of 180 days
from the date of installation.
Labor charges:
•Are included in the warranty for replacement parts installed
during the original warranty period. After the end of the
original limited warranty period, replacement parts labor
shall be covered for a period of 180-days from the date of
installation.
warranty
LIMITED WARRANTY
Under these limited warranties, Pacbrake’s factory will repair
or replace without charge, any part returned to us, freight
prepaid, which our examination discloses to our satisfaction
to have been defective within the warranty coverage period
measured from the date of delivery of the product in question
to the original user.
Pacbrake Company will pay for all reasonable necessary
repairs to damaged engine components in which a Pacbrake
retarder has been properly installed, provided the damage is
established to be a direct result of a defect in the Pacbrake
Exhaust Brake occurring under normal use and service during
the first three (3) years/100,000 miles (whichever shall occur
first) on brake assembly and one (1) year/100,000 miles
(whichever shall occur first) on attaching, controlling, and
related parts.
No engine damage coverage shall be provided beyond this time.
This warranty will not apply to any part or parts which have
been altered or repaired, or to parts which have been
subjected to misuse, abuse, neglect, or accident, or to parts
which have been improperly applied, or installed. Improper
installation, application, or substitution of parts not
manufactured or approved by us shall void this warranty.
Pacbrake product must have been maintained according to
service information in Pacbrake Driver’s Guide - form L5046.
PACBRAKE’S SOLE LIABILITY AND YOUR EXCLUSIVE
REMEDY IS LIMITED TO THE OBLIGATIONS SET FORTH
HEREIN AND PACBRAKE SHALL NOT BE LIABLE FOR ANY
SPECIAL, INDIRECT, OR CONSEQUENTIAL DAMAGES.
If the product should become defective within the warranty
coverage period an authorized Pacbrake distributor shall be
notified by you within ninety (90) days of your having notice of
a defect. If a Pacbrake Distributor is unable to correct the
problem or if you have any questions regarding this warranty,
write to the following address giving full details of the problem
including proof of purchase, the model and serial numbers of
the product involved.
USA:
Canada:
Pacbrake Company
1670 Grant Avenue
Blaine, WA 98230-5161
Pacbrake Company
19594 - 96th Ave.
Surrey, BC V4N 4C3
Warranty registrations must be completed either online
or via mail using the provided warranty card in your
Pacbrake product kit. All warranty registrations must
be submitted within 30 days of the installation date.
800.663.0096
www.pacbrake.com
L3020.03.28.07
Pacbrake® is a registered trademark of Pacbrake Company. Printed in Canada.
YOUR RIGHTS
Manufacturer Warranties
& Aftermarket Products
You the consumer have the right to upgrade or add to your vehicle without affecting the warranty.
The addition of a Pacbrake product will not void the manufacturer
warranty on your vehicle. As with any aftermarket product, be it
mudflaps or oil filters, the onus is on the dealership to prove that
an aftermarket product was responsible for the failure of a vehicle
manufacturers component. You have the right to choose the product
and the product manufacturer whether they are “approved” or not.
As the owner of a vehicle that is under warranty coverage by
the vehicle manufacturer you are protected by federal law - the
Magnuson-Moss Warranty - Federal Trade Commission Improvement
Act of 1975. Under the act, aftermarket equipment does not void
a vehicle’s original warranty unless that warranty clearly and
conspicuously states that aftermarket equipment voids the warranty.
Most states have legislation or statutes that further protects the
owners of vehicles.
In other words, if the warranty statement that was provided with
the vehicle does not say that aftermarket products will void your
warranty then no dealership can by law refuse or arbitrarily void the
warranty on the vehicle. This does not mean that the dealership must
perform warranty repairs on the aftermarket product, and in fact if the
aftermarket product was responsible for the failure of a warrantable
component, the owner or installer / manufacturer would be liable for
those repairs. It is up to the dealership to prove (not just say) that the
aftermarket product caused the failure and if you the consumer find
that the dealership has not adequately provided evidence to support
their claim you have the legal right to demand the dealership comply
with the warranty. If you are being unfairly denied warranty, the
Federal Trade Commission monitors compliance with warranty law
and can be reached at (202) 326-2222.
What to do if a dealership denies or “voids” your warranty because
you have a Pacbrake product installed on your vehicle:
1) Prior to the dealership beginning any repairs, have them
contact the Pacbrake Warranty Administrator at 800-663-0096
and Pacbrake will attempt to resolve the issue immediately.
2) Have the dealership provide you with their warranty denial
in writing (Chances are they will not as this could be used
against them in arbitration).
3) Contact the Federal Trade Commission at the above number
and formally register a complaint.
4) If the dealership still insists that the warranty be denied
because of the installation of a Pacbrake product, have the
dealership provide you with all the failed parts.
If it is determined that a Pacbrake product was not responsible for
the failure of a warrantable vehicle component, Pacbrake will support
the customer through the warranty arbitration process. In the unlikely
event that the Pacbrake product caused the failure and Pacbrake was
advised at the onset of the failure, Pacbrake will cover the affected
parts and labor at the prevailing flat rate.
Pacbrake uses considerable resources in research and development
to ensure that its products are designed within the rigorous
specifications of the engine manufacturer. Pacbrake products are
subjected to extensive quality testing and procedures to continually
make improvements. Pacbrake supports the products it manufactures
to the fullest extent with industry leading warranties, including
progressive damage, and guarantees.
For copies of the Magnuson - Moss Act contact the Federal Trade Commission in your area or phone (202) 326-2222.
It’s your right ... it is your choice ... that’s the law!
www.pacbrake.com 800.663.0096
Pacbrake is a registered trademark of Pacbrake Company. Printed in Canada.
L3018_Rev2.30.07.2015