Pac Brake C44045

[Tony D]

Folks,



I apologize if this is a redundant post! I have a 2006 Dodge 3500 4x4 CTD 48RE Mega Cab Dually. I just purchased the new PAC BRAKE C44045 from a member on this site (jelag), great price BTW!



Questions:

1. Anyone put one on and anything to watch out for during install?

2. How well is it working with the PCM?

3. Any tricks to using it?

4. Does it void the warranty?



Thanks,

Tony

 

[wcjp]

I didn't bother removing the wheel liners. Some find it easier to do so. Loosen the exhaust clamp to help position the Ebrake. I found a fuse extender thing at Autozone for the keyed power source. The fuse extender turns one fuse into two with a power lead. I dremmelled small hole in the fuse box lid. I think I used the seatbelt chime. Off the lead from the fuse extender I added a relay to power the keyed source for the compressor. I wasn't able to fish out the plastic plugs in the ECM. Had to disconnect both batteries and disconnect the ECM. This caused a very temporary engine code.

 

[HGreen]

I removed the wheel liners, getting old and like to see where I'm working. Also had to remove the PCM connectors to remove the rubber plugs, used a piece of board and a bottle jack to get the exhaust pipe to join back up with the exhaust brake fully. As to the wiring, I has previously printed out a copy of the Jacobs exhaust brake instructions, and found their instructions for connecting to a switched source better than PacBrakes. Since I have a 6 speed, I added a clutch switch to end the activiation of the PacBrake every time I shifted. I added the PacBrake shifter mounted switch instead of the toggle provided, but since you have the automatic, the provided toggle will work fine. Have fun installing, mine took about 2 hours for the mechanical (remember I'm getting old) and about 4 hours for the electrical. On the electrical, study how the connectors come apart, it will make things easier, especially the ones down on the front of the engine.

 

[SSalzer]

Do yourself a favor, remove the fender wells. It takes all of about 10 minutes to do. You'll be able to get at the ECM plugs very easily this way. It also makes getting the brake into position alot easier as well as tightening and loosening the exhaust clamps. Otherwise the install is straight forward. The only hiccup I had was that the wires for the relay pack were not long enough to mount it where they recommend (by the driver's battery). I ended up zip tying them to the firewall. Then, I followed the directions and had no problem. The PRXB works great. You'll like it. I got mine from Jelag too.

 

[Pacbrake]

If you have any questions during the install feel free to call our tech suport department 1 800 663 0096 we will be able to walk you through any problems you might come across

 

[JGheen]

I just installed my PAC brake about 2 weeks ago. Great product and pricing from Jelag.

I too say remove the fender wells, takes 5 minutes and lots of access to the engine from both sides. I took the tires off as well since I needed to rotate them anyway.

Removing the ECM plugs was easy. I used some small needled nose pliers and got them out. One of them got kind of pushed in and I was able to get it out with my trusty scribe hook, enough to grab hold of it with the pliers. I used the same needle nose pliers to assist pushing in the ECM wires as my fingers were too larger to push the white wire all the way in with the other wires around it.

The brake went in very easy and was probably the easiest part of the whole job. The entire install took about 5 hours, I just took my time and the most time consuming part was routing the air lines and wires, zip tying them all nice and neat. I will probably one day move the air tank to a different location but it has been working great in the directions recommended spot on the bump support bracket.



Joe

 

[Tony D]

Thanks friends! I do appreciate the advice, knowledge and time all of you took to post the info. I'll let you know how how it goes.

Tony

 

[jelag]

Or you can give us a call as well... . 800. 445. 4696...

One last point not mentioned... please after a couple hundred miles check the clamp between the turbo and brake... I'm guessing you'll find it a little loose... once it's tightened you should be good for the life of the truck... .

PacBrake is now starting to ship Air Horn Kits and Air Bag Kits... .

 

[Tony D]

Well, I started the Pacbrake install today only to quit. Reason: I loosed the v-band clamps at both sides of the elbow and even took the nuts off and still could not get either clamps to brake free of the of the elbow. I hit them with a rubber mallet and no luck. Truck is practically new with only 21,000 miles. I am familiar with v-band clamps as I work with them in aviation. They are used quite frequently on engines. Any advice?

Thanks,

Tony

 

[jelag]

Tony... .

They must have known you were going to try and remove it... . and its glued down.....

We sometimes have to take a punch and working from where the bolt goes through the clamp nudge it away from the housing... . If all else fails hit it harder... . Cummins has them on the shelf locally, don't remember the price...

We have had 2 in the past year with lots of installs that got the better of us... in both cases the bolt broke when we were trying to torque it... ... don't have a clue why... . but the tight ones, have always come loose...

 

[Tony D]

Well, got the clamps off but becuase they were both gaulded on they had to be punched/chiseled off thus they're garbage now. Where do I get the clamps and does anyone have a part number? The local Dodge dealers are of no help. The act like I'm speaking French. Trucks down until I get them!



Any help much appreciated!



Tony

 

[SBeretz]

Well, you guys made me nervous, because I haven't checked my clamps since I installed the brake about a 1ooo miles ago, and both clamps were still tight but one took about 3/4's of a turn. I don't think it was loose, just never really cranked down on it when I installed the brake. Overall, I couldn't imagine pulling a heavy trailer without one. My trailer and truck brakes are great but the exhaust brake is just really nice and will save me alot of brake jobs in the future. Scotty

Again, another satisfied customer from JELAG (Jim) and would reccomend the PACBRAKE to anyone. Install was a little bit of a bear with having to pull the ECM and run the wires, but overall, very worth it. Scotty

 

[Tony D]

Everything was completed this weekend. All in all, very easy install except for the clamp of course. Problem was that the truck had the wrong clamp installed when it was built thus the reason it broke. It was a 1/2" too small and had lots of stress. I installed the correct one and all is well.

FYI: clamp pn: 05174050AA



A great investment for sure and a special thanks to Jelag for the pricing and Jack for the help!

 

[JGheen]

PacBrake is now starting to ship Air Horn Kits and Air Bag Kits... .

Jim, are those PAC brake air bag kits the ones you sell?



Joe

 

[jelag]

JGheen

Yep... my personal trucks have another brand on them because at the time I needed them, PacBrake hadn't decided to build them... I've spent some time at the PacBrake factory and Bill Lang there looked at one of my trucks during their testing phase... . It worked good for both of us... as I learned I had a problem with my install, and he learned that the brackets on my truck were not as strong as they had thought and some redesign was in order...

I would have no problem using their product if I had to change... I've ordered a new 5500 but I assume it will be sprung like a truck... Its in shipping right now... .

We're still waiting on some of the numbers to fill the line but they are getting them in the warehouse..... we have installed them both... the air horn kit functions well I must say.....

 

[KaiHartman]

Will you Pac brake suppliers please PM me? I'm looking for information and pricing on one of these units for an 05 truck w/6 speed. However, I am wondering--do I have to had the clutch safety switch in order to get the brake to disengage in between shifts?? Or would I have to manually turn it off if I do not wish to install the clutch switch??



Also, does anyone recall what the two clamps ran from Cummins ($$)?



Thanks!!

 

[HGreen]

I have an 06 and the "hiss" everytime I shifted about drove me nuts. I installed a home made clutch switch. Got a switch from NAPA that is made to adding backup lights or alarms to manual shift trucks. Its a little bulky but works. made a braclet the bolted to a support to the left of the clutch petal, hole already there. Hooked to the actuator is a stiff spring about 3 inches long that engages the clutch petal. I have it set up so that it will also will break ground for the fast idle, when I ever get around to getting it activiated by the dealer.

 

[KaiHartman]

HGreen,



I appreciate the input on this! I'm wondering how loud it is..... I'm not bothered by a little noise (the whine from the 200 GPH FASS, the constant rattle from the Double Disk SB clutch anytime the clutch is in, the noise from the straight stacks, or the sound of air through the 6" intake system )..... It's all just a part of the experience if someone chooses to ride in my truck!



Would anyone be remotely interested in getting me a digital sound clip of this sound in their truck during a short drive? Do you think it will really bother some people?



Perhaps I'll just purchase and install the brake, and prepare myself to install a clutch switch if need be. I also have the high idle, but chose not to install a clutch switch then for numerous reasons, the first of which being the extra unnecessary work required.



THANKS again for the quick heads up!!! Can anyone PM me the cheapest price they found on these units? Did your unit INCLUDE the compressor or did you have to purchase that separate??

 

[JHaines]

Hi Guys, I purchased a pac brake in Feb 2007 and I really love it, the only thing I wish I would of gone to jelag's shop, for the install. the local shop here has installed jake brake fo me before, with no problem. My truck is a 2004. 5 automatic, which they told me was a real problem. they had my truck for 4 days, and on the phone with Pacific Clutch, maybe 20 or more times. now the compressor works when the engine is cool, but on the highway, after everything gets warm, the compressor quites. and of course no jake brake. I hope the have an answer by tomorrow.

 

[HGreen]

Kai -- I just found it annoying after a while. I kept getting comments like I didn't know that Dodge Diesels had air brakes. Also, since the brake was particially activiting each time the go petal was released, it in affect was trying to slow the engine each time I would shift.