Engine/Transmission (1998.5 - 2002) 3rd gen exhaust brake on 2nd gen!!!!

[Cummins724]

I just wish that I would have taken pictures of the inside of the exhaust brake to show you guys how to rotate the shaft. It can be explained better if anyone needs help. If you go through with this mod, take some pics please for fellow members. I was really proud of myself after figuring this one out!! LOL onestackedram, did you notice how if you didn't rotate the actuator 180* how it would hit the A/C lines etc. ?

 

[DCreed]

724- in flipping the actuator rod 180 doesn't it now operate in reverse? is this brake's valve able to work correctly this way? I know some (like those with a spring loaded bypass) are not.

 

[Cummins724]

724- in flipping the actuator rod 180 doesn't it now operate in reverse? is this brake's valve able to work correctly this way? I know some (like those with a spring loaded bypass) are not.

No it doesn't, you are also turning the bracket that the actuator hooks to. Basically what you are doing is just turning it from 12 o'clock to 6 o'clock position. The actuator still turns the butterfly valve in the same direction. If you look at this pic, the actuator clips on to the bracket which is actually part of the shaft. The shaft goes through the butterfly valve & is held in by a dowel pin. I took that dowel pin out & rotated the hole shaft, actuator 180* as a assembly. The butterfly valve stays in place. It is hard to explain, over the computer.

View attachment 67713

Here is a pic of the inside of a exhaust brake. You could imagine the shaft going through the butterfly valve where the dowel pin is located.

View attachment 67714

 

[DCreed]

Clear as mud!:-laf I got it now ,thanks!

 

[Cummins724]

I'm glad because that took some time to find those pics. LOL

 

[AH64ID]

Thats a pretty sweet setup, I really like my Jake... Did you have to change the exhaust valve springs?

 

[Cummins724]

Thats a pretty sweet setup, I really like my Jake... Did you have to change the exhaust valve springs?

No, the 24v trucks already have 60lb springs from the factory.

 

[SHobbs]

I talked to Jacobs about doing this a while back. They told me that the 03 and up brakes have ( if memory is correct ), a smaller hole in the center of the flapper. The 02 and down is larger. The only downside IF the 03 is smaller is higher temps while using the brake which if you have a pyro it's no big deal. Like I said I am going by memory here, I deleted the email response a while back.

 

[AH64ID]

No, the 24v trucks already have 60lb springs from the factory.

Good

I talked to Jacobs about doing this a while back. They told me that the 03 and up brakes have ( if memory is correct ), a smaller hole in the center of the flapper. The 02 and down is larger. The only downside IF the 03 is smaller is higher temps while using the brake which if you have a pyro it's no big deal. Like I said I am going by memory here, I deleted the email response a while back.

EGT's shouldn't be horrible when braking since there isn't any fuel thru the injectors when the brake in engaged... other than warmup, which a little extra wouldn't hurt, I have never seen more than 625 on mine...



The smaller hole will provide more braking at lower rpm, and "may" cause more back pressure at higher rpms, but really under 99% of braking it wont be an issue... . really who brakes from 2800+ all that often?

 

[Cummins724]

I talked to Jacobs about doing this a while back. They told me that the 03 and up brakes have ( if memory is correct ), a smaller hole in the center of the flapper. The 02 and down is larger. The only downside IF the 03 is smaller is higher temps while using the brake which if you have a pyro it's no big deal. Like I said I am going by memory here, I deleted the email response a while back.

The 03-04 brakes are only 3 1/2" diameter at the exhaust flange, 04. 5 up are 4" all the way. Wonder if 03-04 have the same size hole in the butterfly as 04. 5?

 

[SHobbs]

Cummins724,



Not sure on that. I asked about the exhaust brakes on the newer models due to them having a 4" exhaust compared to the older at 3". I told them that a future turbo upgrade would need the 4" exhaust and can I use an exhaust brake for a newer model. Thats when they explained the difference in the hole in the flapper between the two.



Of course they don't recommend doing it but, we all we will find a way and we have. Nice to see someone has done it now we all know it can be done.

 

[Cummins724]

It is a simple easy mod. I am here to answer any questions that you guys may have if you decide to do it.

 

[SnoKing]

Move the control solenoid to the firewall. Engine has too much vibration. SNOKING

 

[Cummins724]

Pacbrake tells you to mount it on the airhorn as I have it, no problems yet, but I understand what you are saying.

 

[AH64ID]

Move the control solenoid to the firewall. Engine has too much vibration. SNOKING

My solenoid was on the firewall... Huge sound resonance thru the cab, now its on the battery box where it was supposed to go in the first place.

 

[Cummins724]

I just bought another 04. 5 exhaust brake on ebay for $305. Brand new!!! I got it for my brother in law, just wanted to let you guys know that there are still deals on ebay. Here is the link. http://cgi.ebay.com/ebaymotors/ws/e...viewitem=&item=300196296220&_trksid=p3907.m32

 

[Cummins724]

Got some pics to show you guys, this may explain it better.

View attachment 67900



View attachment 67901



View attachment 67902 Pic showing butterfly valve & dowel pin



View attachment 67903 Another pic of the dowel pin.

 

[Cummins724]

Got a few more showing a better view of the dowel pin & clip that holds the pivot ball on to the butterfly shaft. I am just trying to post as many details as possible while I have a brand new exhaust brake sitting here.

View attachment 67907 Remove these 2 bolts to turn actuator bracket 180* then reinstall.



View attachment 67908 Here is a better shot of the dowel pin.



View attachment 67909 See the clip on the pivot ball.



View attachment 67910 Another pic of the dowel pin.



View attachment 67911 Zoom in on this pic & it shows the clip that needs to be removed to disconnect the pivot ball.

 

[Cummins724]

Here is a picture of the horse shoe clip which attaches the pivot ball to the butterfly valve arm.

View attachment 67912