2nd Gen Non-Engine/Transmission BD Ehaust Brake Problem

[MBNicholson]

I have a 1996 5.9 dually, 5spd w/Gear Vendors OD, Banks pwr pack, BD Super B single turbo, BD1037135 exhaust brake, and numerous other upgrades. I bought this truck new, it is cherry, 172,00 miles and I pull 13,000 lb+ 5th wheel. In the fall of 2011, we were coming down the hill from our house in Sequim, WA and discovered our PAC brake was inoperative. Made a quick stop at Erik's to discover the brake cam was worn out. Drove it to AZ with no exhaust brake! In AZ, since I had to replace the exhaust brake, I ordered the Super B, the above described remote exhaust brake and a 4" exhaust system. It met all my expectations. Since the installations, we have only made 1 1/2 trips to AZ and around a 4000 mile trip last summer while pulling the trailer. Around a year ago, I started to hear sort of a harmonic sound coming out of around the transmission (I thought), when engaging the clutch on start up under load. It sounded almost like a throw out bearing. About a month ago, I was up the road at a neighbor using his lift to do some cosmetic work under the truck, and when leaving up a steep hill from his house with the window down discovered I could play a tune duplicating this sound. He got outside of the truck, and we immediately decided this was an old fashioned rattle. Back to the lift, and we quickly discovered you could take the exhaust brake vacuam can and shake it up and down and duplicate the rattle. Took it down to Erik's and they quickly said the pin (a bolt) and mounting bracket hole it rests and pivots in, were all worn, and they are waiting for the parts from BD to fix it. Personally, I am really concerned with this as it just looks like a poor design as I see it. The vacuum can has to rotate a small amount in this hole, it's metal on metal, and I cannot see how it could not wear. I talked to Hector at BD, who I was told was their exhaust brake expert, and at his request I sent him some pictures and a description of what had happened. I have not had a reply from him.

So, has anyone out there run into this before? Am I looking forward to going through this again in the next year or two? Mike Nicholson

 

[turbod98]

I am on my 4th bracket now (98 12v Qcab 5sp 4X4 317K miles) over the last 9 years. I too have had the worn pivot holes, but all have had weld failures between the upper and lower pivot bracket welds.
The last one that I installed I re-welded the new piece with a more substancial weld. The next one, I will billet machine from 316 SS and increase the pivot points to accept bushings.
Very annoying when the bracket fails,the weight of the vacuum cylinder will cause the brake to activate - increadable how much coal one of these trucks can roll :-laf when that happens you need to pull over and disconnect it on the roadside. The truck will barely move out of its own way due to closed valve.
I have also spoken to BD, and while they are sympathetic, but to date they have not improved the bracket design to my knowlege. Other than that, I think the brake is one of the best out there.

Good luck with yours as well,

HP