How to Install Truck Exhaust Brakes

A great way to get more miles of out each set of expensive rotors and brake shoes is to add an exhaust brake into your truck's brake system. An exhaust brake is a butterfly valve that restricts the expulsion of the gases from the engine when in use. An exhaust brake will decrease the RPM of an engine by creating a back pressure in the exhaust system that lowers the compression inside the engine itself. By lowering the engine's compression, you instantly decrease speed without using the existing braking system to accomplish this task. You can spend less money on your brakes by learning to install this powerful braking tool.

Difficulty: Moderately Easy

Instructions

Things You'll Need:

• Utility saw (Saws-All)
• Razor-blade cutter
• Drill
• Drill bits
• Wrench
• Socket set
• Torque wrench
• Screwdrivers (Phillips/flat)
• Allen wrenches
• Wire connectors (crimp style)
• Hand-held shrink heater/blower

1. Remove the ground connection from the negative post of the truck's battery. Loosen the negative post clamp from the battery using the correct closed-end or Allen wrench. Tie down the negative battery lead, away from the battery, to prevent an electric short or electric shock while installing a truck exhaust brake.

2. Locate the factory rubber grommet that protects the plastic conduit (containing control wiring) that comes from the engine compartment into the passenger compartment, through the firewall under the steering wheel. Use a screwdriver to remove that grommet. Then dismantle the lower dashboard. Remove two screws that secure the lower dashboard to the truck and save them for reinstallation later. The upper portion of the lower dashboard is secured by two clips you release by gently pulling back on the top corners of the lower dashboard. Send the wiring to the Power switch, computer controller and accelerator pedal sensor through the firewall into the passenger compartment, using the opening you created when you removed the grommet in the firewall.

3. Secure the computerized brake control box, power switch and accelerator switch inside the passenger compartment of the truck. The computer control box should be located out of sight under the dashboard, and the power switch should be placed in an easily reached location for quick access while driving. Run wiring to each component and connect using the male and female adapters supplied with the brake system. Finish the passenger-compartment wiring by connecting the system to the truck's fuse box. Located behind the emergency brake pedal, the exhaust brake must be wired into the appropriate fuse to operate correctly. Refer to the exhaust brake manual for the correct position (Pin E5, D5, E5, F5, F6). The accelerator sensor is installed into the existing accelerator pedal assembly via a wire "T" clamp splice into the brake light wiring, so the computer can track the accelerator during braking. Reinstall the dashboard using the factory clamps and screws.

4. Find the coolant temperature sensor that is located on top of the engine, near the front and usually behind the oil-supply tube. Run the exhaust brake wiring that ends in the coolant sensor connector to that location. Replace the factory sensor with the exhaust brake sensor. Be sure not to damage connectors. Always gently wiggle and massage any connectors that are hard to separate. Clean any dirty wiring prior to attempting to separate factory connections. Connect the factory sensor wiring to the exhaust brake wiring harness that has the adapter to receive this connection.

5. Remove the factory air box and filter to gain access to the base plate of the air box. Loosen, but do not remove, the band clamps that secure the air intake tubes to the intake manifold, and disconnect the tubes using the appropriate screwdriver. Remove the airbox and intake tubes in one piece and keep for reinstallation. Remove the air box baseplate by loosening the retaining bolts that secure it to the truck. Mark and drill three 3/8-inch holes that will be used to secure the airbrake compressor inside the engine compartment. Attach the compressor to the air-box base plate using nuts, bolts and washers. Reinstall the air box base plate with the compressor connected; be sure the compressor is in a good position. Now connect the pneumatic hose to the outlets of the compressor by pushing the hose into the push and lock the hose fittings. Reinstall the air box, leaving the air hose ends so they are easily reached when needed. Power the compressor by connecting its power-supply wire to the battery junction box, and connect it to the brake-wiring harness using the supplied exhaust-brake system connectors.

6. Cut out a section of existing exhaust tubing large enough to accommodate the exhaust brake-tube body above the transmission crossmember under the truck. This piece is cut from the rear side of a four-bolt flange connection that is located in the exhaust system, under the passenger compartment. Using exhaust band clamps, install the exhaust brake tubing into the space provided by removing the old portion of the factory exhaust tubing. Tighten the clamps to the appropriate torque so the clamps seal the exhaust-brake tubing onto the existing factory exhaust. Then reseal the exhaust system at the four-bolt flange using the supplied flange gasket and tightening the flange nuts to 30 lbs. of torque. Run the exhaust-brake pneumatic air hoses from the compressor to the exhaust-brake armature on the newly installed exhaust brake and connect using push-and-lock connectors.

Tips & Warnings

• Use wiring shrink wrap to cover all wiring connectors that are open to the environment. To avoid any electrical problems, remove any avenues for moisture to enter the electric circuit via connections made during installation. Do not squeeze and cut pneumatic hoses. To avoid damage to this important tubing, always cut with a sharp razorblade and without pressing down on the tubing.
• This truck exhaust-brake installation is performed after the engine has been in operation. Always avoid contact with any extremely hot metals to avoid burns and injuries.

Resources

• Banks Power--Truck Parts