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

[Cummins724]

I just recieved my new super htb2 62/71/14 turbo in the mail today. I ordered it with a 3rd gen exhaust turbine housing... . so that I can use a 3rd gen exhaust brake. It wasn't a hard mod at all, but a change had to be made. The actuator had to be reversed [pointing down instead of up] & that was actually quite simple. The "flapper" inside of the exhaust brake is turned by a shaft through the center of it. That shaft hooks to a lever on the outside of the housing which is run by the actuator. The shaft is hooked to the "flapper" by a pin [like a dowel pin] which holds them together as a unit. I removed the pin & spun the lever 180 degrees... . Then I reinstalled the pin into the shaft. This allowed me to reverse the position of the actuator downward. It looks like it was built for the 99 when looking at it mounted on the truck. I haven't tried the brake out yet because my solenoid,wiring etc. aren't in yet, but I will post the results as soon as I try it out. I just wanted to let you guys know that it is possible with a little work.

 

[Froadin]

I have researched this one and asked around (emailed with Jacobs), and knew it would work. But didn't know the little details that would come up.

This is something that I figured would be my answer to a larger turbo and keep my exhaust brake.

If you don't mind me asking, what did you pay for the brake itself (not the wiring, hoses, etc, just the elbow/brake itself). Jacobs said I could use all my existing wiring/hoses, just swap the brake itself.

Do you have any pictures?

And how are the clearances around it now?

And what downpipe are you running?

 

[Cummins724]

Do you have any pictures?

And how are the clearances around it now?

And what downpipe are you running?[/QUOTE]

I don't have a digital camera, but I'll answer any questions that you have. I bought the brake for $300. brand new on ebay. The actuator has about 1 inch of clearance between it & the a/c line. The thing really looks like it was factory installed. The exhaust pipe was a easy fix too... . I got a 3rd gen downpipe & cut the flange off & welded it to my 99 downpipe & she was done. The clamps are available from dealer or High Tech etc. If you live nearby... I'd be happy to show you/help you with fabrication.

 

[Froadin]

Would LOVE to see it, but don't even know where you are.

That doesn't sound like too bad of a deal!

Heck, just having the much larger elbow that the new brake has would be an improvement, let alone having it on the bigger turbo!



Btw, do you tow a lot? And if so, how does this turbo work for you?

 

[Froadin]

Oh yeah, what year was the exhaust brake from?

Knowing that the 2004. 5 and newer ones have true 4" elbows, that makes a difference.

 

[Cummins724]

I just noticed that you are from Fort Jones... . I am from PA, so that won't work. I got the 04. 5 brake [4"], but I haven't tried it out yet [or the turbo] because I had to order a fitting for the oil line. The one in the top of the turbo broke off when I tried to take it out of my old turbo. I will get it fixed tomorrow & let you know. The exhaust brake came with no solenoid, wiring etc. I am going to order the parts soon. I own a excavating business & tow equipment daily [mini excavators & skid steers] around 15k pounds. As soon as I get the fitting... I'll be towing for a good break-in to get the new turbo use to being abused. I will post the results tomorrow if all goes well.

 

[Froadin]

I need to find a brake setup like that! It would be perfect seeing as I already have everything else.

Looking forward to your results!

 

[Cummins724]

I will keep my eyes open for it, but it seems they are hard to find. Last week ..... I saw a complete 04. 5 brake kit sell on ebay for $600 new. I've been calling around trying to find a solenoid,wiring & pedal switch for my 99. I want to run the brake off a pedal switch only... . so I don't get a delay on it from the ecm. I talked to several people from banks, pacbrake etc. yesterday, but I was trying to find these local. Seems like I have to order them from banks. The parts are only $300. so that means that I have $600. in this system & $50. in a downpipe. I think it will be worth every cent.

 

[Froadin]

What about a stock Jacob's wiring kit for the 2nd gen? Just use the switch that comes with it, and a simple switch on the pedal that is normally triggered by the ECM wire. I think that is how others have done it for a faster setup.

The pedal switch can be bought from Summit or Jegs pretty easy. Usually something like a nitrous switch, etc.

 

[Cummins724]

I priced the jacobs parts & they wanted $300 for the solenoid only. That is why I called pacbrake, banks etc. The nitrous switch is a good idea, but where can I get a solenoid? I want to order the parts tomorrow, cause I just tried out the new turbo & it is awesome. I haven't towed with it yet, but I think it will be OK. The super turbo spools about 150 rpm later than the htb2 62/14, but damn is it alot faster from 10psi to 45psi. The brake will just make my setup alot sweeter!

 

[Froadin]

For those costs, find someone that is selling their jacob's brake setup, preferably one with a BAD brake. Should be a LOT cheaper then $300 for just the solenoid!

 

[Cummins724]

I posted a wanted ad in the classified & only got responses from guys with complete kits. I need to get this working soon, because I am tired of changing brake pads. Banks solenoid is $100 & wiring harness, pedal switch etc. was $200. That is the cheapest parts that I have found. If anyone is reading this message who has these parts... Let me know

 

[NoSeeUm]

Do a search for solenoid valves. My Banks kit used a MAC. A comparable STC can be bought for around $25.



I got 4 MAC 3-way valves off E-Bay for around $50.



MAC

STC



Jim

 

[Cummins724]

I found a cheaper setup @ Advance Diesel Technology. I talked to Doug & he got me a nitrous switch & control valve for $120. That's not to bad... . bringing grand total for a 04. 5 exhaust brake conversion to $480. +shipping parts. I can't wait to try it out. Thanks for your help though. I just got your message a little too late.

 

[Cummins724]

I got the parts in today & I gotta say damn is that brake awesome with a load. I have it hooked to the throttle switch & it is really fast to engage. I absolutely love this brake, but I want to ask you guys a question. I've never had a exhaust brake before & was wondering if it is normal to hear a hissing sound when the brake is engaged? I think it is the pressure from the brake forcing through the tiny hole in the "flapper" that I am hearing, but I just want to make sure. When engaged it kinda sounds like a dragging brake pad... . any help is appreciated.

 

[NoSeeUm]

I got the parts in today & I gotta say damn is that brake awesome with a load. I have it hooked to the throttle switch & it is really fast to engage. I absolutely love this brake, but I want to ask you guys a question. I've never had a exhaust brake before & was wondering if it is normal to hear a hissing sound when the brake is engaged? I think it is the pressure from the brake forcing through the tiny hole in the "flapper" that I am hearing, but I just want to make sure. When engaged it kinda sounds like a dragging brake pad... . any help is appreciated.

If you are talking about the hissing at the end of the tail pipe with the truck at idle, yes mine does that also. Other than that I hear no hissing, when I am using the brake, just a different engine sound from the cab. The exhaust note hisses a bit at those times.



Jim

 

[Froadin]

Yeah, the hissing is the hole in the plate. This is the 'safety' that keeps it from completely closing the exhaust off.

My truck hisses LOUDLY! I forget sometimes in traffic and people look at me VERY odd! LOL. You can see people start looking around to find the 'odd' sound.



Glad to hear that this brake works great! How have your EGT's been lately?

 

[Cummins724]

Glad to hear that this brake works great! How have your EGT's been lately?[/QUOTE]

The turbo is awesome... I couldn't have got a better turbo. The most egt that I've seen is 1100 degrees & 16k behind me [skid steer, 3 attachments & bucket] I recommend this turbo to anyone who tows & I know that they will love it as I do. Exhaust brake is working great. I got to try it out today on 5% grades & I gotta say... It really surprised me how well this thing stops a load at low RPM's. I finally got the perfect setup for towing. I never expected the hissing sound & thought that I had a vacuum leak, but I'm glad to hear that it is normal. I appreciate the feedback.

 

[Cummins724]

Ok guys, I've been getting some pm's asking how I got a 3rd gen exhaust brake on my truck. I've also been asked if I had some pics, I'll post them up, but don't mind the mess, I've got some spring cleaning to do. Has anyone else done this mod yet? :-laf

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[onestackdram]

Wow that cleared alot of things up for me atleast. My wastegate is in a different position than yours as my turbo was made from scratch and just happens to have things slightly different. So now I know it can be done and done well.