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Directmount

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September 2018
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DirectMount EXHAUST BRAKES APPLICATION: 2003-2007 Dodge Trucks equipped with 5.9L Cummins diesel engines and manual transmissions 2006 & 2007 Dodge trucks equipped with 5.9L Cummins diesel engines and automatic transmissions 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 lock-up controller. Contact Pacbrake Customer Service @ 800.663.0096 for more information. Pacbrake kit information and applications covered in this manual: C14030 Pacbrake kit is a fixed orifice design for 2003 Dodge diesel trucks built up to January 4th, 2004 with a Cummins 5.9L engine and a manual shift transmission only. C44030 Pacbrake kit is a PRXB design for 2003 Dodge diesel trucks built up to January 4th, 2004 with a Cummins 5.9L engine and a manual shift transmission only. C14045 Pacbrake kit is a fixed orifice design for 2003 Dodge diesel trucks built after January 5th, 2004 with a Cummins 5.9L engine and a manual shift transmission only. C44045 Pacbrake kit is a PRXB design for 2003 Dodge diesel trucks built after January 5th, 2004 with a Cummins 5.9L engine and a manual shift transmission only. This kit also fits on Dodge trucks built after July 26th, 2005 with Cummins 5.9L 610 ft-lbs of torque and automatic transmissions. 1 Before starting the installation, please read the entire installation manual carefully. Check that your Pacbrake kit contains all the necessary parts. See page 3 for the kit contents list. Pacbrake offers three optional accessories to enhance your exhaust brake system that you may want to consider before starting the installation (see page 4). I N S TA L L AT I O N M A N U A L - L 2 0 3 2 Pg. 2 Dodge 2003 and Newer KIT CONTENTS: C14013 - Control Group A F B C A 14 x C11618 B 1 x HP1019 C 2 x P60100 D 1 x C11609 E 72” M8685 F 1 x C241 G 1 x C20089 H 1 x C11628 I 1 x P01304 J 1 x C10315 K 72“ M8280 L 1 x C20507 M 51” M8014 C20013 Mounting Group N 2 x C3003 O 2 x C3004 P 2 x C3002 Q 2 x C10468 R 1 x C10444 S 1 x C789 T 2 x C653 U 2 x C10473 8 x C10406 V 4 x C3470 4 x C10843 E D I J H G K Q R N O P S T V M L U C11592 - Air Hose Kit Tywraps Brass Fitting Self Drill & Tap Screws Pressure Switch Nylon Tube (blue) Remote Inlet Air Filter Harness Compressor, 12 Volt Toggle Switch Switch Plate Nylon Air Brake Tube Compressor Bracket Conduit Spacer Long, M10 Spacer Spacer, M8 M10 x 1.5 Screw Capscrew 3/8” Flat Washer Flat Washer #10 Flat Washer Screw Nyloc Nut C11614 - Air Tank Group BB AA GG EE LL DD FF LL KK CC DD II JJ HH AA BB CC DD EE FF GG HH II JJ KK LL 1 x C11940 1/2 Gallon Air Tank 192” M8280 Nylon Air Brake Tube 1 x C11737 Brass Fitting 2 x HP1019 Brass Fitting 1 x C11996 Fitting 2 x P60100 Self Drill & Tap Screws 1 x C11815 Quick Release Bracket 1 x M8677 1/4” Brass Coupler 1 x HP1153 1/4” NPT Close Nipple 1 x HP1152 Bulk Head Fitting 1 x C11848 1/4” NPT Hex Plug C18018 (Bolt) + C3004 (Spacer) + C18007 (Lock Washer) + C653 (Flat Washers) + C11572 (Nut) C20173 - Harness C40110 C40111 C20405 C20406 I N S TA L L AT I O N M A N U A L - L 2 0 3 2 PRXB Exhaust Brake (C44030 kits) PRXB Exhaust Brake (C44045 kits) Fixed Orifice Exhaust Brake (C14030 kits) Fixed Orifice Exhaust Brake (C14045 kits) Pg. 3 Dodge 2003 And Newer Dodge 2003 and Newer Dodge 2003 And Newer SWITCH-PAC GEAR SHIFT LEVER SWITCH Optional Accessories 2 Number DodgePart 2003 AndC18042 Newer ( f o r m a n u aSWITCH-PAC l t r a n s m i sGEAR s i o n sSHIFT only ) LEVER SWITCH SWITCH-PAC GEAR SHIFT LEVER SWITCH Part Number C18042 An optional gear available for SWITCH-PAC GEARshifter SHIFT switch LEVER is SWITCH (for manual transmissions only) Part Number C18042 manual transmission vehicles through Pacbrake Part Number C18042 (for manual transmissions only) distribution system. Pacbrake part numberisC18042 An optional gear available for ( f o r m a n u a l t r a n s m i s s i o nshifter s o n lswitch y) An optional gear shifter switch 5 is available for manual for shifter diameter /8". manualof transmission vehicles through Pacbrake transmission vehicles though distribution An optional gear shifterPacbrake switch is Pacbrake available for distribution system. part number C18042 system.manual Pacbrake part number C18042 for shifter 5 transmission vehicles through Pacbrake for shifter diameter of /8". MECHANICAL THROTTLE SWITCH GROUPS diameter of ⅝”. system. distribution Pacbrake part number C18042 5 for shifter diameter of /8". throttle switch groups Pacbrake offers mechanical MECHANICAL THROTTLE SWITCH GROUPS to speed up the activation of the exhaust brake. Pacbrake mechanical MECHANICAL THROTTLEoffers SWITCH GROUPS Part # C14037 throttle switch groups to speed up the activation of the exhaust brake. 2003 M/Y trucks with manual transmission MECHANICAL THROTTLE SWITCH Pacbrake offers mechanical throttle GROUPS switch groups Part # C20135 # C14037of the exhaust brake. to speed up Part the activation Pacbrake offers throttle switch groups to 2004 M/Ymechanical trucks transmission 2003with M/Ymanual trucks with manual transmission speed up the of the exhaust brake. Part # activation C14037 Part # C20135 2003 M/YC14037 trucks transmission Part Number 2004with M/Ymanual trucks with manual transmission Part # C20135 2003 model year trucks with manual transmissions 2004 M/Y trucks with manual transmission Part Number C20135 2004 model year trucks with manual transmissions OPTIONAL CLUTCH SWITCH INSTALLATION KIT Part Number C20097SWITCH OPTIONAL CLUTCH ( f o r m a n u a l t r a n s mCLUTCH i s s i o n sSWITCH o n l y ) INSTALLATION KIT INSTALLATION OPTIONAL KIT Part Number C20097 Provides brake disengagement during clutching. Part Number C20097 OPTIONAL CLUTCH SWITCH INSTALLATION KIT (for manual transmissions only) Locate the two capscrews at the clutch lever. Re(for manual transmissions only) Part Number C20097 move the screw closest to the rear of the vehicle. brake during clutching. ( f o r m a n u aProvides l transm i s s i odisengagement ns only) Install the Pacbrake switch on this capscrew Locateofthe capscrews at the as clutch lever. ReProvides disengagement thetwo Pacbrake during Provides brake disengagement during clutching. shown. Tighten the capscrew. Adjust the switch clutching. Locate the two capscrews at the clutch lever. move the screw closest to the rear of the vehicle. Locate the two capscrews atclutch the clutch lever. onthe thescrew bracket so when therear is fully released Remove closest to Pacbrake the ofswitch the vehicle. Install the on thisRecapscrew as move the screw closest to the rear of the vehicle. Install the switch on this capscrew as shown. the Pacbrake clutch arm contacts the switch arm causing shown. Tighten the capscrew. Adjustthe the switch TightenInstall the capscrew. Adjust the adjustment switch the bracket the Pacbrake switch on when thisoncapscrew asis the switch to click. the byclutch moving on Check the bracket so the fully released so when the clutch isThe fully released the clutch arm conshown. Tighten the capscrew. Adjust the switch clutch pedal. switch should click in the freethe clutch arm contacts the switch arm causing the tacts the switch arm causing the switch to click. Check on bracket so theCheck clutch isiffully releasedby moving the playthe movement of when the clutch pedal,the not readjust. switch to click. adjustment the adjustment byarm moving pedal. The switch the contacts the switch arm causing Cut clutch the white wire atthe theclutch clutch switch, using thethe 2in the freeclutch pedal. The switch should click should switch click intothe freeplay movement of the clutch click. Check the adjustment by moving the push-on terminals supplied, of crimp clutch and connect to playAfter movement pedal, pedal. If not, readjust. performingthe Step 25 cut the if not readjust. clutch pedal.Cut The switch should click in the freethe terminals on the either terminal of the clutch switch. whiteUsing wire the at the clutch switch, using the 2 white wire at the clutch switch. 2 push-on play movement of theterminals clutch pedal, if notcrimp readjust. terminals supplied, push-on crimp and connectsupplied, to the terminalsand connect to Cut the white wire at the clutch switch, using on either terminal ofthe the2clutch switch. on either terminal ofthe theterminals clutch switch. push-on terminals supplied, crimp and connect to the terminals on either terminal of the clutch switch. I N SI N TA NA UN AU L A- LL 2- 0L3220 3 2 S LTLAALTL IAOTNI OM NA M I N S TA L L AT I O N M A N U A L - L 2 0 3 2 P g . P4G . 2 PG Dodge 2003 And Newer Dodge 2003 and Newer Dash Switch Installation 33 Dodge2003 2003And AndNewer Newer Dodge Consult with the owner or operator of the vehicle for Dash Switch Installation their preference of dash switch location. The loca- tionwith shown the photo is our of recommendation for Consult the in owner or operator the vehicle Dash Switch Installation Dash Switch Installation a vehicle equipped answitch automatic transmission. for their preference of thewith dash location. The Consult with theowner owner operator thevehicle vehicle for Vehicles with manual transmissions, weofofrecomlocation shown in the photo is ouroror recommendation for for Consult with the operator the their preference of dash switch location. The locamend an optional lever on/off The switch their preference dash mounted switch location. locaa vehicle equipped withshift anofautomatic transmission. For tion shown in the photo is our recommendation for tion shown in the photo is our recommendation (C18042). vehicles with manual transmissions, we recommend an for a vehicle equipped with an automatic transmission. a vehicle equipped with an automatic transmission. Once thelever switch location has switch been chosen, if a optional shift mounted on/off (C18042). Vehicleswith withmanual manualtransmissions, transmissions, werecomrecomVehicles we dash switch is being installed, drill a 1/2" hole to Once the switch location hasshift been chosen, if aon/off dashswitch mendan anoptional optional shift lever mounted on/off switch mend lever mounted accommodate the toggle switch. Connect the white (C18042). switch is being installed, drill a ½” hole to accommodate wire to(C18042). the top terminal and the black wire to the Oncethe the switchlocation location been chosen, the toggle switch. Connect the whitehas wire to the top ififaa Once switch been bottom terminal. Connect the has other endchosen, to 1 a good 1 /2" hole to dash switch is being installed, drill a terminal and the black wire to the bottom terminal. dash switch is being installed, drill a /2" hole to chassisaccommodate ground. The the white wireswitch. is connected later. If toggle Connect thewhite white Connect the other end tothe a good chassis The accommodate toggle switch.ground. Connect the installing a shift lever mounted on/off switch, follow wire thetop toplater. terminal andthe theblack wire the wire totothe terminal and totothe white wire is connected If installing ablack shiftwire lever the instructions provided withinthe theother C18042 kit. bottom terminal. Connect end to a good bottom terminal. Connect the other end to a good mounted on/off switch, follow the instructions provided chassisground. ground.The Thewhite whitewire wireisisconnected connectedlater. later.IfIf chassis within the C18042 kit. 33 installing shift levermounted mountedon/off on/offswitch, switch,follow follow Exhaust Brake Installation installing aashift lever 4 4 NOTE: It isthe advised to disconnect boththe negative the instructions providedwithin within the C18042kit. kit. instructions provided C18042 I N Sterminals TA L L E R O P T I O N ( n o t m a n d a t o r y ) battery ExhaustBrake BrakeInstallation Installation Exhaust Some installers remove the front wheels and I NSS TAALLLLEE OPPTTthe I ONN at toor ryy) ) which secure wheelhouse Exhaust Brake Installation IN T RR O IO ( (nnoot t mmaannddasplash 4 8 screws 4 shields. Doing this allows for easier access to the INSTALLER OPTION (not mandatory) Some installers remove the front wheels and Some installers remove the front wheels and exhaust elbow and the engine ECU on the drivSome installers remove the front wheels and 8 screws 8 screws which secure the wheelhouse splash 8 screws secure the wheelhouse splash ers side of the which vehicle. To remove the wheelhouse which secure the wheelhouse splash shields. Doing totothe shields. Doingthis thisallows allows for easieraccess access the for easier splashshields. shield Doing completely, the ABS cable will need to this allows exhaust for easier access to the exhaust elbow and exhaust elbow and the engine ECU on the drivelbow and thesplash engineshield. ECU on the drivbe disconnected from the ersside side the vehicle. Toremove remove thewheelhouse wheelhouse the engine ers ECU onofof the drivers side of the vehicle. To the vehicle. To the Caution: If removing the front wheels for easier splash shield completely, the ABS cable will needtoto remove thesplash wheelhouse splash shield completely, the shield completely, the is ABS cable will need access, make sure the vehicle supported be disconnected from the splash shield. ABS cable be willdisconnected need to be disconnected from the splash from the splash shield. properly. Caution:IfIfremoving removingthe thefront frontwheels wheelsfor foreasier easier shield. Caution: &ENDER 2AIL &ENDER &ENDER &ENDER 2AIL 2AIL &ENDER &ENDER 3CREWS access,make makesure surethe thevehicle vehicleisissupported supported access, 5 5 CAUTION: properly. If removing the front wheels for easier properly. REM O V E sure F A C the T O Rvehicle Y ELBO access, make isWsupported properly. At the R turbocharger locate the 2 “V” clamps fastenR EEMMOOVVEE FFAACCTTOORRYY EELLBBOOWW ing the exhaust elbow to the turbo and header pipe. Atthe thedamage turbocharger locate the2when 2“V” “V”clamps clamps fastenTo prevent to the threads removing, turbocharger locate the fastenREMOVEAt FACTORY ELBOW the exhaust elbow to turbo and header pipe. apply ing aing drop of oil as close to the nut as posthe exhaust elbow to the turbo and header pipe. To prevent damage to the threads when removing, At thesible, turbocharger, locate the 2 “V” clamp fastening then remove both. Save both “V” clamps for To prevent damage to the threads when removing, apply adrop drop oilas asis close the nuttwo asTo posthe exhaust elbow to the turbo and header pipe. afactory ofof oil close totothe nut as posreuse.apply The elbow indexed with roll sible, then remove both. Save both “V” clamps for prevent damage to the threads when removing, apply sible, then remove both. Save bothelbow “V” clamps pins. These pins should remain in the and a iffor reuse. The factory elbow is indexed with two roll reuse. The factory is indexed with two roll drop of oilthey as close to be theremoved nutelbow as possible, remove not, MUST from thethen turbo outlet pins.These These pinsshould should remain theelbow elbow andifif pins. pins remain ininfactory the and both. ﬂSave both “V” clamps for reuse. elbow ange. These are for alignment ofThe the elbow at the not, they MUST be removed from the turbo outlet not, be removed from the turbo outlet is indexed withthey two MUST roll pins. These pins should remain truck assembly plant and are not required. Inspect ﬂange. ange.These Theseare arefor foralignment alignmentofofthe theelbow elbowatatthe the ﬂ in thethe elbow and face if not,ofthey MUSTfor becarbon removed from imsealing the turbo or other truck assembly plant and are not required. Inspect truck flange. assembly plantare andfor are not required. Inspect the turbo outlet These alignment the perfections. If necessary, clean or repair toof assure aimthesealing sealingface faceofofthe theturbo turbofor forcarbon carbonororother otherimthe elbowgood at the truck assembly plant and are not required. seal will be made as no gaskets are used. perfections.IfIfnecessary, necessary,clean cleanororrepair repairtotoassure assureaa Inspect theperfections. sealing face of the turbo for carbon or other goodseal sealwill willbe bemade madeas asno nogaskets gasketsare areused. used. good imperfections. If necessary, clean or repair to assure a good seal will be made as no gaskets are used. 3CREWS 3CREWS 7HEELHOUSE 3PLASH 3HIELD 7HEELHOUSE 7HEELHOUSE 3PLASH 3PLASH 3HIELD 3HIELD 55 I N S TA L L AT I O N M A N U A L - L 2 0 3 2 I INNSSTTAALLLLAATTI IOONN MMAANNUUAALL - - LL22003322 I N S TA L L AT I O N M A N U A L - L 2 0 3 2 PG. 3 PPGG. . 33 Pg. 5 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. Dodge 2003 and Newer 6 6 7 7 With the original turbocharger to elbow “V” clamp placed loosely over the turbocharger outlet, insert CAUTION: Use carehousing if installing a PRXB exhaust the Pacbrake into the exhaust system and brake. rotate When the handling brake assembly sure housingthe until the turbo ﬂangebe and the not to damage the regulator spring arm. exhaust brake’s pressure ﬂangeand arelever parallel. Install the turbo clamp loosely ﬁrst and rotate the With the original turbocharger “V” clamp Pacbrake until the outlettoﬂelbow ange aligns with the placed header loosely pipe. over the turbocharger outlet, is insert the Once proper alignment achieved Pacbrake housing into the and (8.5 rotate torque the turbo sideexhaust clamp system to 75 in-lbs N•m). the housing until theinstall turbo the flange andside theclamp exhaust Now loosely outlet and then brake’storque pressure are parallel. turbo theflange outlet clamp to 100Install in-lbsthe (11.3 N•m). 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 Compressor Installation 75 in-lbs (8.5 N•m). Now, loosely install the outlet side clamp and then torque the outlet clamp to 100 in-lbs Remove the three capscrews shown with arrows in (11.3 N•m). the photo. Not all vehicles have the three forward capscrews shown and removal of the front two capscrews may not be necessary. These vehicles AIR COMPRESSOR SUB-ASSEMBLY: will require the longer spacers. Locate the poly bag containing the air compressor mounting bracket, fasteners and mounting hardware. Place one M10 flat washer on each of the two M10 capscrews. Insert one capscrew into the ring terminal (air compressor/solenoid ground) of the air compressor electrical harness. 88 Position the 1 small OD spacer provided and on the Install the two capscrews into the bracket assembly as air intake horn. Choose the correct spacers for your shown. Make note of the mounting bracket cut out, as it application and position them over the two front MUST be to the right side. mounting locations. RIGHT SIDE I N S TA L L AT I O N M A N U A L - L 2 0 3 2 I N S TA L L AT I O N M A N U A L - L 2 0 3 2 PG. 4 Pg. 6 Dodge 2003 and Newer 9 Using the four 10/32 x1” machine screws, eight #10 flat washers and four Nyloc nuts LOOSLEY attach the compressor to the bracket as shown, Compressor head must face the opposite side from the cut out on the bracket, machine screw must be installed as shown in the photo for STEP 10 (threaded ends pointing upwards). Ensure the leg of the Pacbrake harness is between the air compressor and the mounting bracket. 10 11 Tighten the four mounting screws and nuts until the washers first contact the isolator and then tighten TWO additional turns. Do not over tighten. COMPRESSOR INSTALLATION Remove the four capscrews indicated in the photo with arrows (three with BLACK arrows and the one with a WHITE arrow). Not all vehicles will have the three forward capscrews shown in the photo; therefore the removal will not be necessary. Vehicles without the forward capscrews require two long spacer tubes and those with the capscrews will require two short spacers, both lengths are provided. Remove the capscrew holding the oil dip stick tube down (shown with the WHITE arrow), discard this bolt, a new fastener and spacer will be installed in STEP 13. I N S TA L L AT I O N M A N U A L - L 2 0 3 2 Pg. 7 Dodge 2003 and Newer 12 Position the correct length spacers in the locations shown in the photo (with arrows). All installations require the small O.D. spacer on the air intake horn. NOTE: An engine with the forward capscrews is shown in the photo 13 Install the compressor assembly over the 3 spacers. Obtain the best clearance of the compressor to coolant hose and compressor to intake horn as possible. Torque the 2 large capscrews (shown with the arrow, under the compressor) to approximately 32ft-lbs, (43 N•m). Torque the allen head capscrew to 18 ft-lbs (24 N•m). Place the spacer provided over top of the mounting hole for the oil dip stick. Using the longer M8-1.25x30mm bolt, spacer and flat washer, secure the dip stick tube to the intake horn, torque to 15ft-lbs, (20 N•m). Install the pressure switch using thread sealant, into the open port on the compressor assembly as show in the photo. CAUTION: This kit includes “push to connect” airline fittings. They require the end of the airline to be round, square and cleanly cut to ensure the internal seal will not leak. The airline must only be cut with a sharp razor knife or hose cutter NOTE: The blind threaded port on the compressor head facing the front of the vehicle remains open. I N S TA L L AT I O N M A N U A L - L 2 0 3 2 Pg. 8 Dodge 2003 and Newer 14 Install the Black nylon airline provided to the solenoid port marked “CYL”. Route this airline around the front of the engine to the exhaust brake air cylinder, keeping it away from heat sources and moving parts. Install the 90˚ fitting supplied into the air cylinder using thread sealant and connect the airline. Cut the airline to length with a sharp razor knife. Secure the airline with the tie-straps provided. CAUTION: This kit includes “push to connect” airline fittings. They require the end of the airline to be round, square and cleanly cut to ensure the internal seal will not leak. The airline must only be cut with a sharp razor knife or hose cutter 15 Install the 1/4”NPT-1/4” push on barbed hose fitting on to the plastic filter housing. Locate the Blue nylon hose and connect one end to the barbed fitting on the intake filter. Install the compressor air intake filter into the hole located in the radiator support bracket behind the driver side headlight as shown in the photo. Route this line up to the compressor, and connect the other end to the push to connect fitting on the bottom side of the compressor. 16 Install the ¼” NPT to ⅛” NPT nipple into the air tank. Install the two push to connect airline fittings into the ends of the Tee fitting. Install the Tee fitting on to the top of the nipple, as shown in the photo. Install the ¼” NPT plug fitting or drain valve (optional) into the bottom of the tank. Apply thread sealant to all fittings installed. Air leaks will cause the compressor to cycle more often reducing its life expectancy. I N S TA L L AT I O N M A N U A L - L 2 0 3 2 Pg. 9 ﬁttings installed. Air leaks will cause the compressor to cycle more often reducing its life expectancy. Dodge 2003 and Newer Choose a location tothe mount the air tank a location to mount air tank such as such on as on 1712Choose the drivers side bumper support brace shown the driver’s side bumper support brace shown in the in the " holes on 3 ¼"tocenter to accomphoto. two 3/8on photo. Drill twoDrill ⅜” holes 3¼” center accommodate modate the tank mounting holes. Provided the tank mounting holes. Provided are two spacers are andtwo spacers and fasteners for mounting. you prefer fasteners for mounting. If you prefer another If location to another location to mount the air tank, theto pressure mount the air tank, the airline provided may need be switch need to be extended. substituted for wires a longmay piece. Dodge 2003 And Newer 18 Connect the Black nylon airline to the remaining fitting at the compressor. Route to the to topthe of remaining the air tank. Cut at Connect the 8 ft.itairline ﬁtting I knife. N S T AConnect L L AT I O N MANUAL - L2032 the airlinethe to length with a sharp razor the compressor. Route it with the two RED wires ¼” airline to to the either fitting in the tank. Secure theofairline “Tee” ﬁtting installed in the top the air away fromtank. moving parts the and¼" heat sources Connect airline to theusing ﬁttingthe in tiethe tank straps provided. and connect the wiring harness connector to the 13 PG. 5 Using thepressure remainingswitch lengthconnector. of airline, Secure connectboth one the endharness and airline away from moving parts to the remaining fitting in the air tank, consulate theand heat using the tie-straps provided. customer sources for a preferred location for the quick connect airline coupler. Route this air line to this location and connect to the coupler. Wiring Harness Installation 19 All Models: 14 WiringUsing Harness Installation the self tapping screw provided, secure the two relay receptacles to the side of the inner fender ALL MODELS: on the drivers side of the vehicle. LOCATE THE PACBRAKE HARNESS PROVIDED Using the self tapping screw provided, secure the two relay receptacles to the inner fender on the driver’s side of the vehicle. Install both relays. Locating an Ignition Power Source Under the2003 hood, Model route theYear leg ofVehicles: the Pacbrake wiring 20 15 Locate pin connector on the passenger side harness with the the two 14 Weather-Pac connectors to the ﬁrewall. Pin 13 will a dark blue wiretowhich air compressor. Connect the be female connector the should be a 12 volt positive ignition power source. male connector at the compressor and connect the Connect the 10 to amp fused link to this male connector thered female connector atwire. the pressure switch. Secure the harness with the tie-straps provided. 16 2004 and 2005 Model Year Vehicles: 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. Connect the 10 amp red fused link to this wire. I N S TA L L AT I O N M A N U A L - L 2 0 3 2 17 2006 and Newer Model Year Vehicles: Locate the TIMP Module in front of the drivers’ side Pg. 10 sources sources using using the the tie-straps tie-straps provided. provided. Wiring Harness Installation Wiring Wiring Harness Harness Installation Installation Models: Dodge and Newer 142003All Using the self tapping screw provided, secure the 14 All Models: Models: 14 All Using the self screw provided, the two relay the side of the secure inner fender Using the receptacles self tapping tapping to screw provided, secure the two relay receptacles to side on the drivers side of the vehicle. two relay receptacles to the the side of of the the inner inner fender fender Locating an Ignition Power Source on on the the drivers drivers side side of of the the vehicle. vehicle. NOTE: Both negative battery terminals will need to be temporarily reconnected to ensure 12 volts DC exists. 21 Locating anVEHICLES: Ignition Power Source 2003 MODEL YEAR an Power Locate theLocating 14 pin connector on the passenger side Locating an Ignition Ignition Power Source Source 2003 Model Year Vehicles: firewall. Pin 13 will be a dark blue wire which should 2003 Model Year Vehicles: Locate the 14 pin connector on the passenger side 2003 Model Year Vehicles: be a 12 volt positive ignition power source. Using the Locate the 14 pin connector the passenger side ﬁrewall.the Pin14 13pin willconnector be a darkon blue which should Locate on thewire passenger side T-tap provided, connect the 10 amp red fused link of theshould ﬁrewall. Pin 13 will be a dark blue wire which be a 12 volt positive ignition power source. Connect ﬁrewall. Pin 13 will be a dark blue wire which should Pacbrake be harness to this wire. 12 volt positive source. thea fusedignition link to power this wire. be a10 12amp volt red positive ignition power source. Connect Connect the 10 amp red fused link to this wire. the 10 amp red fused link to this wire. Dodge 2003 And Newer 15 15 15 2004 and 2005 Model Year Vehicles: 16 2004 and 2005 Model Year Vehicles: 2004 & 2005 YEAR VEHICLES: LocateMODEL the two 24 pin connectors the driver’s 2004 and 2005 Model Year on Vehicles: 22 16 16 Locate the two 24 pin connectors on the driver’s Route the red fused wire with the eye terminal to Locate the two 24 pin connectors on the driver’s side of the side of the ﬁrewall. One connector is grey and Locate two 24 pin connectors on the driver’s 18 side of the ﬁrewall. One connector is grey and the theOne positive batteryis terminal the firewall. connector grey andand theconnect. other is black. otherofisthe black. In theOne black connector, pin B4 side ﬁrewall. connector is grey andwill thebe other is black. In the black connector, pin B4 will In the black connector, pin B4 will be a pink wire with a a pink wire with a grey tracer. This wire should bebe a other is black. In the black connector, pin B4 will be a pink wire with a grey tracer. This wire should be grey tracer. This wire should be a 12 volt positive ignition 12pink voltwire positive power This source. thea a with ignition a grey tracer. wireConnect should be a 12 volt positive ignition power source. Connect power source. Using T-tap connectConnect the 10 the 10 volt amp red the fused linkprovided, topower this wire. 12 positive ignition source. the 10 fused link wire. amp red fused linkred of the Pacbrake harness 10 amp amp red fused link to to this this wire. to this wire. and Newer Model Year Vehicles: 17 2006 2006 Newer Model Year Vehicles: Locateand the TIMP Module in front of the drivers’ side 17 2006 and Newer Model Year Vehicles: 17 2006 AND NEWER MODEL YEAR VEHICLES: Locate the TIMP Module in front of the drivers’ Connect theTIMP black wire with theoneye terminal to side the battery.the Release the lock tabs the side of the 23 19 Locate Module in front of the drivers’ side Locate thenegative TIMP module in front of the driver’s side battery. Release the lock tabs on the side of the battery terminal or a good chassis ground. TIMP. This will allow the TIMP to be removed as battery. Release the lock tabs on the side of the battery. Release the tabs on side of the TIMP. TIMP. This will allow thethe TIMP to removed Secure withlock the tie-straps provided. an assembly. Under the unit, locate “G”. TIMP. This will allow TIMP to be be connector removed as as This will allow the TIMPUnder to be removed as an assembly. an assembly. the unit, locate connector “G”. Cavity 14 will Under be a grey pink tracer. This an assembly. the wire unit,with locate connector “G”. Under theCavity unit, locate connector “G”. Cavity 14 will be This 14 will be a grey wire with pink tracer. wire should volt wire positive power. Cavity 14 willbebea a12grey withignition pink tracer. This a grey wire with pink tracer. This wire should be a 12 wire be 12 ignition Usingshould the T-Tap connect the 10power. amp red wire should be a aprovided, 12 volt volt positive positive ignition power. volt positive ignition power. Using the T-tap provided, Using the connect fused link to this provided, wire. Using the T-Tap T-Tap provided, connect the the 10 10 amp amp red red connect the 10 amp red fused link of the Pacbrake fused link to this wire. fused link to this wire. harness to this wire. I N S TA L L AT I O N M A N U A L - L 2 0 3 2 II N S A N M Nspecial ST TA AL LL LECM AT T II O O N of MA AN NU UA AL L -- LL 22 00 33 22 Route the black wire with the pin PG. 6 P PG G .. 6 6 Route the black wire with the special ECM pin of the 24 20 the harness to the engine’s ECM (drivers side of harness to the engine’s ECM (driver’s side of the engine) the engine) if you are installing an ECM By-pass if you are installing an ECM bypass system (see note system. (See note below). below). The EngineModule Control(ECM) Module (ECM)to is the bolted to the The Engine Control is bolted left side of the engine below the intake left side of the engine below the intake manifold. manifold. At the engine locate the two The connectors. the engineAtECM, locate ECM, the two connectors. front The front connector is a 60 pin and the rear is a 50 pin. connector is a 60 pin and the rear is a 50 pin. If installing thebypass ECM bypass system, NOTE: If Note: installing the ECM system, now now would be a convenient time to install. Follow would be a convenient time to install. Follow the the instructions provided instructions provided in that with kit. that kit. 21 I N S TA L L AT I O N M A N U A L - L 2 0 3 2 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 +%9 %NGINE#ONTROL-ODULE%#- 7AY#ONNECTOR 7AY#ONNECTOR Pg. 11 Note: If installing the ECM bypass system, now would be a convenient time to install. Follow the instructions provided with that kit. +%9 %NGINE#ONTROL-ODULE%#- 7AY#ONNECTOR 7AY#ONNECTOR Dodge 2003 and Newer From inside the cab, locate the grommet in the floor. 25 21 ﬂoor.hole Make a small hole in foronly. the Make a small in the grommet forthe thegrommet white wire From inside the cab, locate the grommet in the wirethe only. InsertECM the end withthe thehole. special ECM Insert the white end with special pin into pin into the hole. NOTE: If installing the optional clutch switch If installing optional clutch switch PN# (C20097),Note: now would be athe convenient time to install. C20097, now would be a convenient time to install. Follow the instructions provided in that kit. Follow the instructions provided with that kit. Dodge 2003 And Newer Dodge 2003 And Newer Dodge 2003 And Newer Recover this wire and route it to the engine ECM. At the 50 Recover this wire and route it to the engine ECM. At the 26 22 pin (rear) connector, locate pin #39. Remove the sealing 50 pin (rear) connector, locate pin #39. Remove the ECM. At the 50 Recover this wire and to the engine plug. Be careful not to route pushI ititNin. 22 S TA L L AT I O N M A N U A L sealing plug. Be careful not to push it in. pin (rear) connector, locate pin #39. Remove the sealing plug. Be careful not to route push in.the this wire and itit to theinsert engine ECM. thewith 50 Once the Recover sealing is removed, insert white wire Once theplug sealing plug is removed, the whiteAt wire 22 pin (rear) connector, locate pin #39. Remove the sealing PG. 7 L2032 with the special ECMECM “PIN”“PIN” into cavity #39. #39. PushPush in in until seated. the special into cavity Once the sealing plug is removed, insert the whiteinwire with plug. Be careful not to push it in. until seated. Gently on wire the wire to ensure the is pin is Gently pull pull on the to ensure the pin locked place. the special ECM “PIN” into cavity #39. Push in until seated. locked in Use place. 51”of piece of conduit supplied to the white wire. theUse 51"the piece conduit supplied to protect Gently pull on theplug wireistoremoved, ensure the pin is place. Once the sealing insert thelocked white in wire with protect the white wire. Usespecial the 51"ECM piece“PIN” of conduit supplied protect the seated. white wire. the into cavity #39.to Push in until At the 50 connector, locate pin is#42, and in remove Gently pullpin on(rear) the wire to ensure the pin locked place. the sealing Be careful not tosupplied push it in. Once the plug Use the plug. 51" piece of conduit to protect thesealing white wire. Atremoved, the 50 pininsert (rear)the connector, locate andECM remove is black wire, withpin the#42, special pin,the sealing Be careful not to push it in. Once sealing from theplug. compressor harness, into cavity #42. the Push in untilplug Connector A Connector B (60 Pin) (50 Pin) is insert black wire, with the#42, special pin,the the 50Gently pin (rear) connector, locate pin andisECM remove Engine ECM At the 50 At pinremoved, (rear) connector, pin #42 and seated. pullthe onlocate the wire to ensure the pin locked the compressor harness, cavity #42. the Push in until sealing plug. BeBe careful notnot to push it in. Once sealing plug Connector A Connector B remove the sealing plug. careful tointo push it in. infrom place. (60 Pin) (50 Pin) Engine ECM seated. Gently pull on the wire to ensure the pin is locked is removed, insert the black wire, with the special ECM pin, Once the sealing plug is removed, insert the black wire Secure both ECM wires with theinto tie-straps provided in place. from the compressor harness, cavity #42. Push in until Connector A Connector B with the special ECM pin from the compressor harness (60 Pin) (50 Pin) Engine ECM Gently pull on the wire to ensure the pin is locked into cavityseated. #42. Push in until seated. Gently pull on the Note: the sealing plug with is in the too tie-straps deep to remove, or you cannot SecureIf both ECM wires provided in place. wire to ensure the pin locked push twoisECM pinsininplace. far enough to lock in place, use a 1 5 6 10 Note: If the sealing plug is inthe too deep to remove,oforthe you50cannot 4mm hex wrench to remove capscrew pin Secure both ECM wires with the center tie-straps provided Secure both ECM wires with the tie-straps provided. 11 20 push the two ECM enough to lock place,the useplug a 21 1 connector from the pins ECM.inIffar it is necessary to in remove 5 6 1030 31 40 4mm hex wrench to remove the capscrew of pin If the sealing is in toocenter deep to remove, orthe you50 cannot NOTE: If Note: the sealing plug isplug in too deep to remove, from the ECM, both the batteries must be disconnected ﬁrst to 11 20 2141 connector from the ECM. it enough is in necessary to in remove the 45 46 50 30 push the two ECM in Iffar to lock place, useplug a or you cannot push the two ECM pins far enough prevent damage to pins the ECM. Once the connector is removed 31 1 5 6 10 40 from the ECM, both the must be disconnected ﬁrstpin to hexuse wrench to remove the center capscrew the 50 to lock in4mm place, a 4mm hex wrench to remove from the ECM, push the batteries sealing plug out from theof ECM side with 11 41 45 5020 damage to ECM. the ECM. Once thefrom connector is removed 21 30 connector from the Ifpins it is necessary tothe remove there-install plug 50 Pin46 the center capscrew ofInstall the 50both pin connector aprevent small probe. into the correct cavities, 31 40 from the ECM, push the sealing plug out thebatteries. ECM side with the ECM, both the must befrom disconnected ﬁrst to ECM. If itfrom is necessary to remove the plug from the the 50 pin connector andbatteries tighten. Reconnect the Engine 41 45 46 50 50 Pin a small probe. Install pins into the connector correct re-install prevent damage to theboth ECM. Once is removed ECM, both the batteries must be disconnected first cavities, CAUTION! thedamage 50 connector andsealing tighten. Reconnect from thepin ECM, push the plug out fromthe thebatteries. ECM side with Engine to prevent to the ECM. Once the connector The white wire goes into the ECM pin #39. This is a ground input and under no circumstances 50 Pin should a small probe. Install both pins into the correct cavities, re-install is removed from the ECM, push the sealing plug out CAUTION! 12 volts positive applied to this circuit. Damage to the ECM will result. 50side pin connector and tighten. Reconnect the batteries. from the the ECM withgoes abesmall Install both Engine The white wire intoprobe. the ECM pin #39. This is a ground input and under no circumstances should pins intoCAUTION! the correct cavities, re-install the 50 pin 12 volts positive be applied to this circuit. Damage to the ECM will result. connector and tighten. Reconnect batteries. The white wire goes into thethe ECM pin #39. This is a ground input and under no circumstances should Note: If the wheelhouse splash guards were removed, they may be reinstalled now by following the 12 volts positive be applied to this circuit. Damage to the ECM will result. procedure in reverse. Note: If the wheelhouse splash guards were removed, they may be reinstalled now by following the procedure in reverse. Note: If the wheelhouse splash guards were removed, they may be reinstalled now by following the Check Operation procedure in reverse. I N S T A L L A T I O N M A N U A L - L 2 0 3 2 Pg. 12 Start the vehicle and allow it to idle. Note: The compressor will pump for approximately 2 minutes to ﬁll the Check Operation air tank. Turn the Pacbrake switch to the on position, and the exhaust brake should activate. Slowly raise the Start theRPM. vehicle and allow it to idle. Note: The compressor will(ifpump 2 minutes to newer ﬁll the engines The Pacbrake should shut off above 900 RPM it wasfor onapproximately at an idle). Late 2003 and 23 23 27 23 1 11 21 31 41 5 1 51 11 21 31 41 5 55 51 1 555 11 21 31 41 51 55 6 10 6 56 20 30 40 50 10 60 20 30 40 50 1 5 6 10 11 21 31 1 41 11 21 31 20 30 40 5 45 41 45 60 656 10 1 5 Pin numbers from back side of connector 20 11 30 21 40 31 50 6 46 10 50 20 30 40 46 6 Pin numbers from side of connector 45 46 56 60 back 41 50 10 20 30 40 50 Pin numbers from back side of connector 24 24 24 25 25 Check Operation EC EC EC Dodge 2003 and Newer 28 CAUTION: The white wire goes in to 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. If the wheelhouse splash guards were removed, they may be reinstalled now by following the reverse procedure Dodge 2003 And Newer of Step 4. Dodge 2003 And Newer the red withterminal the eye to terminal to Route theRoute red fused wirefused with wire the eye the 29 18 the positive battery terminal and connect. positive battery terminal and connect. the red fused wire with the eye terminal to 18 Route the positive battery terminal and connect. 30 31 the black wire with the eye terminal to the 19 Connect negative battery terminal or a good chassis ground. Connect the the black wire with the eye terminal to the Secure with tie-straps provided. 19 Connect the black battery wire with the eyeorterminal to the ground. negative terminal a good chassis negative battery a good provided. chassis ground. Secure terminal with the or tie-straps Reconnect both battery terminals. Secure the Pacbrake harness with the tie-straps provided. 20 20 Route the black wire with the special ECM pin of the harness to the engine’s ECM (drivers side of Route the black the special ECM pin of the engine) if youwire arewith installing an ECM By-pass the harness the engine’s system. (Seetonote below). ECM (drivers side of ChecktheOperation engine) if you are installing an ECM By-pass The Engine Control Module (ECM) is bolted to the system. (See noteitbelow). Start the vehicle allow to idle. left sideand of the engine below the intake manifold. The Engine Control Module (ECM) is bolted to the At the engine ECM, locate the two connectors. The NOTE: The compressor will pump for approximately 2 minutes to fill the air tank. left of the engine thethe intake frontside connector is a 60below pin and rear manifold. is a 50 pin. At the engine ECM, locate the two connectors. The If installing bypass system, now Once theNote: maximum system pressure is achieved air compressor will shut off. Wait a few minutes to see if front connector is the aair 60ECM pin and the rear is a the 50 pin. +%9 would be a convenient time to install. Follow the the air compressor cycles. If it does, an air leak exists. Use a 50/50 mixture of liquid dish soap and water, apply Note: Iflooking installing ECMthat bypass system, now Turn the Pacbrake switch to%NGINE#ONTROL-ODULE%#- instructions provided with kit. as to all the fittings for the bubbles, repair necessary. the ON position, and the 7AY#ONNECTOR +%9 wouldshould be a convenient time toraise install. theRPM. The Pacbrake should 7AY#ONNECTOR exhaust brake activate. Slowly theFollow engine’s shut off above 900 RPM %NGINE#ONTROL-ODULE%#- instructions provided withand thatnewer kit. vehicles will disable the exhaust brake at 7AY#ONNECTOR (if it was on at an idle). Late 2003 idle when the coolant 7AY#ONNECTOR temperature is above 170˚F. With a 12 volt test light, power one side to the negative battery terminal. Place the probe endFrom on relay terminal 85locate whichthe connects to pin 42 of the engine ECM. Increase engine RPM and release inside the cab, grommet in the the throttle quickly. The test light should illuminate when ﬂoor. Make a small hole in the grommet for the the engine is decelerating. Keep in mind the ECM has a slight delay exhaust brake. Road test theECM vehicle. Re-torque clamps after the first 100 miles of From inside thethe cab, locate thewith grommet in the whiteactivating wire only. Insert the end the special driving. NOTE: If the the a exhaust brake to operate, ﬂpin oor. Make small hole in fails the grommet for check the for a good connection at the ECM pins #39 and #42. into hole. See note white in step 24.only. It may be necessary to remove the ECM 50 pin connector from the ECM if the wires don’t lock in wire Insert the end with the special Note: If installing the optional clutch switch PN# the connector. pin into the hole. C20097, now would be a convenient time to install. Note: installing the optional clutch FollowIfthe instructions provided with switch that kit.PN# C20097, now would be a convenient time to install. Pg. 13 I N S TA L L AT I O N M A N U A L - L 2 0 3 2 Follow the instructions provided with that kit. 21 21 Dodge 2003 and Newer White C18042- Manual Transmission Only Pacbrake On/Off Switch Optional Shifter Mounted ON/OFF Switch Manual Transmission Only White to Pin 39 Black Black to Ground Optional Clutch Switch C20097 Red Black Black Nylon Airline To Quick Connect Black Nylon Airline Air Intake - Blue nylon airline to connect to filter assembly in step 15 Pressure Switch White Black Nylon Airline To Air Cylinder Pacbrake Air Tank Pacbrake Solenoid Connect to Pin #39 50 Pin Connector "B" View shown is of harness connector installed in ECM Orange 1 45 46 10 Amp Fuse Solenoid Relay 87 50 Connect to Pin #42 Red Red 10 20 30 40 11 21 31 41 connector connector Black 85 86 Compressor Relay 87 86 30 30 Red 85 30 Amp Fuse Driver’s Side Battery + Pos. Red with White Trace Blue Ignition Power Source Optional Compressor On/Off Switch Neg. - *Not provided in this kit Black I N S TA L L AT I O N M A N U A L - L 2 0 3 2 Pg. 14 L2032_REV7.07.09.2012

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