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Pacbrake and GDP secondary fuel filter mount

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Yet another 48re question

ECM controlled exhaust brake on 04.5 auto?

STEVEBROOKS

TDR MEMBER
Did a search before posting, but didn't find anything that matched up...

I'm finally going to install an exhaust brake on my '03, and I'm leaning heavily toward the direct-mount Pacbrake. That said, I do also have the GDP secondary fuel filter mount on the engine by the TPS bell crank housing. I'd greatly appreciate hearing back from anybody that found a way/place to mount the air compressor somewhere other than by the TPS housing. I also have a small compressor for the air-adjustable Rancho shocks mounted on the passenger-side fender between the battery and the firewall, so that area's used up as well.

Thanks in advance for the help!

Steve
 
Hey AH,

Honestly, in addition to it being 15+ years old, that Rancho compressor's kind of small/cheap/noisy; I'm surprised it's lasted this long. I'm inclined to just not mess around with it and find another place to mount the Pacbrake compressor. I'm hoping to hear back from somebody who's mounted the Pacbrake compressor somewhere other than the "stock" position, or can offer some other solution...

Steve
 
I used the OBA I already had, which was a ViAir 450 mounted inside my toolbox. I did add a small 0.5 gallon tank and it worked great.

Do you have a toolbox or canopy?

The last two compressors I’ve installed have been mounted on the bottom of the bed and that’s a nice out of the way location.

With airbags and 19.5’s I’d probably get the PRXB without a compressor and get a little bigger one for multiple uses.

No matter what you’re going to wish you had done this a long time ago.
 
When I upgraded my compressor for my PRXB, I moved it to the outside frame rail, under the front passenger door. 100% duty cycle. Not in freezing temps very often.
 
My personal experience with the Pac Compressor is that it is severely undersized and can't keep up with the demand if you have to cycle the EB continuously on a long grade.
After a short time you run out of air.

You better install a ViAir system right away that has the capacity to deliver more air then the EB can take under the worst circumstances.
 
My personal experience with the Pac Compressor is that it is severely undersized and can't keep up with the demand if you have to cycle the EB continuously on a long grade.
After a short time you run out of air.

Interesting. I have a PacBrake air compressor and so far, I have not had that experience and I just did a 500 mile trip from Crescent City, CA to Baker City, Oregon that involves seven mountain passes. Going down each mountain pass I am turning the exhaust brake on and off several times on the downgrade. I also pass through a 30 mile section of road that has lots of 30 mph curves one right after another with lots of exhaust brake use. I have never experienced what you are saying.

My system has a 1/2 gallon reservoir. When the compressor cycles on, it takes about 10 seconds for it to cycle off. After two applications, the compressor cycles on again.

Does your compressor cycle differently? Is it possible that you have a leak somewhere?

- John
 
It’s a small pump with low duty cycle and low CFM, that is only rated to 158°F.

It’s a much better idea to get a slightly larger compressor with at least a 50% duty cycle and remote mount it away from the engine bay.

@petersonj it’s been a while, but I recall getting a bit more than 2 cycles with my 1/2 gallon tank.
 
it’s been a while, but I recall getting a bit more than 2 cycles with my 1/2 gallon tank.

Likely that you had a direct mount exhaust brake - mine is an in-line, so maybe a little more volume with the added distance of the air line?

- John
 
I installed it, the whole kit, in my buddies truck that uses it in the Swiss alps only.
By cycling I mean, 5-10 seconds on, 5 off, another 5-10 on and so on.. the roads call for that use. The system is down after about 3/4 of a minute. I told him to adjust the usage as good as possible but probably I'll install a better air system into his truck next winter to get rid of it entirely.
 
Thanks all for the replies. Overall, as with many things, I suppose it's better to have too much than not enough, so I'll consider going with a non-Pacbrake compressor. That said, what recommendations for one do y'all have and where did you mount it?

Steve
 
It depends what you wanna do with it, if it is only for the EB

https://viaircorp.com/products/oba-medium?_pos=2&_fid=fa68b9af8&_ss=c

If you also want to air up tires or such then this one

https://viaircorp.com/products/oba-constant?_pos=7&_fid=fa68b9af8&_ss=c

There are other choices but these are the basic ones.

I run this one

https://viaircorp.com/products/oba-continuous?_pos=8&_fid=465eac71b&_ss=c


All of them can be installed along the frame rail under the driver's seat.

Also install one of these

--------https://www.amazon.com/dp/B00CD8G218?th=1&psc=1

Into the line to the EB valve to keep the pressure at a safe level for the EB.
 
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Pacbrake, viair and others have brackets to mount compressors to the frame rail. It can be isolated with som thick rubber/urethane sheet. I think most people mount it on the outboard side of the right frame rail.

I have no issues with the volume of air, but the compressor is indeed limited in capacity.

Pacbrake has a kit for user provided air, it only has one relay, to control the air solenoid, otherwise same as the kit with the compressor.

My 6 speed '03 has the TPS under the battery box, so I guess you have an auto trans. I thought the auto TPS was down lower on the left side. The compressor mounts on top of the cylinder head integral intake just forward of the intake heater grid.

Here is my thread on my Pacbrake install.
https://www.turbodieselregister.com...-pacbrake-kit-on-my-03-5-9l-ho-nv5600.273276/

Charles
 
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Thanks for the suggestions, Ozy. Charles: mine's an early-build (Aug '02) '03 with the 6-speed trans. My TPS bell crank's located right in front of the intake horn under a black plastic cover, over which is where my secondary fuel filter's mounted. I'll definitely look at your thread about the install!

Never having had or used an EB, it brings up the question about its use: do y'all use a shift-lever mounted switch for it or jut leave it "on" all the time?

MANY thanks to all for the info. I'll have more questions to come, I'm sure...

Steve
 
Never having had or used an EB, it brings up the question about its use: do y'all use a shift-lever mounted switch for it or jut leave it "on" all the time?

I have a six-speed as well. I use a velcro mounted momentary floor switch right next to where my left foot rests. Just rotate my foot to use it and since the clutch is used during shifting, I don't have to worry about forgetting to turn the exhaust brake off during a shift.

The switch has a metal case and is very durable. Interestingly, 20 years ago I paid $4.37 for this switch.

- John

upload_2025-3-21_9-21-12.png
 
Never having had or used an EB, it brings up the question about its use: do y'all use a shift-lever mounted switch for it or jut leave it "on" all the time?

MANY thanks to all for the info. I'll have more questions to come, I'm sure...

Steve

With a Manual you leave it on most of the time except you really want to coast.
Me with the Autotrans have it On most of the time except if it interferes with the gear the Trans want to choose and I don't.
 
Never having had or used an EB, it brings up the question about its use: do y'all use a shift-lever mounted switch for it or jut leave it "on" all the time?

You’ll figure it out pretty quick, but on when you want the braking and off when you don’t. When towing my switch is almost always on, driving around town it varies.

A shifter mounted switch was perfect on my NV5600. Let the ECM control the EB and enjoy.


I have a six-speed as well. I use a velcro mounted momentary floor switch right next to where my left foot rests. Just rotate my foot to use it and since the clutch is used during shifting, I don't have to worry about forgetting to turn the exhaust brake off during a shift.

The switch has a metal case and is very durable. Interestingly, 20 years ago I paid $4.37 for this switch.

- John

View attachment 143075

I would definitely not go this route on a 3rd gen. Lots more work than needed when the ECM will control it and let it work with cruise control.
 
The Third Gen ECU does a fine job of controlling the EB, as it is intended to. Pacbrake makes a clutch switch to mount on the top of the pedal so if it is depressed any at all, the EB is deactivated. I asked about this when I bought my kit, and was told to try it first. Indeed, I have found no need for it. If I shift gears S-L-O-W-L-Y and get my foot completely off the accelerator, the brake activates for a split second with a b.u.r.pppp. I usually keep a bit of pressure on the accelerator, not enough to take the engine off of idle, but enough to keep the EB from activating.

When I am not towing, driving locally, I keep the EB off, its annoying to have it on and off, and isn't needed. On the road, pulling the travel trailer, it stays on. I'm not flipping it on and off unless I'm just playing with it, so the switch doesn't need to be at my fingertips. It is, however, within easy reach, as I installed it in the lower cubby hole in the dash, on the far left side (see the pic in my thread).

Keep in mind, Pacbrake also has a line of compressors, from small to fairly large and frame mounting brackets also, as does Viair, and ARB. Pacbrake has suspension "air bags" and controls plus quite a few other products, hence the variety of compressors.

You can verify your part numbers HERE, but the kit for '03-'04 MANUAL SHIFT, WITH the compressor, tank, etc, is C44030 and the kit WITHOUT the compressor (ie. user supplied, including your own pressure switch and operating relay) is C44031.

HERE is the installation instructions for the C44030 kit with Pacbrake supplied air system.

HERE is the installation instructions for the C44031 kit with user supplied air system.

I clipped the attachment out of the instructions for the Pacbrake supplied air system. I think the black object in the right of the pic is your pedal position sensor, which is attached with three large capscrews to the intake. The instructions cover removing the capscrews and installing the SHORT spacers if this is installed, or if not, the longer spacers. I didn't know what this was until you started this thread. MY PPS is under the LH battery box and so I did not have that bracket and capscrews, I used the long spacers. Your only concern is the add on fuel filter, which I think hangs under the intake air horn. If that is the case, it will not be in the way of the compressor installation.

Pacbrake has been thru this a few times, so they have worked out most all of the details.

Please carefully read my comments about how I got 12v ignition on power for the kit. I DO NOT like the way Pacbrake has you tapping into wires in the harness, it can cause corrosion in the wire, and I got my method of getting ignition power from reading the BD Howler kit install instructions.

I bought male and female Aptiv formerly Delphi, Metri-Pack 180 connectors and created a short (about 4 inch) male to female 14 gauge wire connector with an extra wire coming off the positive wire to the inline fuse. This plugs into the fuel filter heater connector and then the vehicle wire connector plugs into the other end of it. The only thing on the circuit is the fuel heater and the amp draw of the Pacbrake is minimal, probably less than an amp. Do as you like, but I don't like splicing into or cutting into vehicle wiring. I prefer "elegant" removable/reversable methods. I cannot find a pic of this but if you need one, I can probably get a decent pic for you.

EDIT: is your filter kit mounted like this?
#ad

If so, you may need to cut the spacers shorter by the thickness of the bracket, but Im not so sure that the bracket isn't going to interfere with the compressor itself.


Charles

Screenshot 2025-03-22 213424.png
 
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