P N # C APPLICATION:

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1 P N # C APPLICATION: DODGE RAM 4WD VEHICLES Pacbrake s 4WD 2 Wheel Low Kit allows the vehicle operator to engage the transfer case into 4WD low range without engaging the front wheel drive, allowing the vehicle to maneuver a trailer into a tight area without the wheel hop associated with 4 wheel drive operation.

2 The market leader because... #1 Exhaust Brake Manufacturer PROVEN PERFORMANCE EXCELLENCE SINCE Pacbrake is the only patented design that s approved, optional and standard equipment with more OE manufacturers than all other makes combined. Why trust your safety AND your money to anyone else? Maximum Retarding/Braking Power Superior design and function provide maximum allowable retarding power for maximum peace of mind. In a standardized test; we will exceed or match any competitive brake on the market. Superior Design PACBRAKE DIRECTMOUNT design mounts on the turbocharger to provide: a) Instant retarding horse power (no time delay) b) Increased reliability c) Easiest installation of all exhaust brakes available. Other brands require more parts, clamps, andinstallation time. Arcor Nitrided Housing & Components* PACBRAKE s Industry exclusive coating process makes Pacbrake the toughest, most durable brake on the market. a) Reduces wear and increases corrosion resistance b) Adds strength and maintains flawless action. * Available on most models. Other brands are more susceptible to rusting, corrosion and seizing up in a harsh exhaust environment. Free Flow Exhaust & Backpressure Limiter PACBRAKE exhaust brakes offer an unrestricted exhaust flow design and provides maximum retarding power without reducing power output. The backpressure limiter guarantees engine safety. Braking power when you need it - without sacrificing engine power. Precision Exhaust Pipe Mounting Surface PACBRAKE s contacting surfaces are precision machined eliminating the need for a gasket. A better fit with less parts. Lower Price AND Less Expensive Installation PACBRAKE technology and quality are available to you at hundreds of dollars less than most competitors. Add to that fewer parts and easier installation (= less labor) and you benefit financially from purchase to installation tolong term performance. Other brakes cost you more upfront, more at installation and more down the road. PACBRAKE Parts & Dealer Network It s one thing to purchase an exhaust brake, but it s another to have parts and/or service available every- Important Note Every effort has been made to ensure that this manual is as complete and comprehensive as possible. However, as changes and updates do occur, we recommend checking our website for the most upto-date manuals and information. P G. 1

3 Getting Started Thank you and congratulations on your purchase of Pacbrake s 4WD 2 Wheel Low Kit. 1 Before starting, check that the kit contains everything shown in the photo. 2 Install the solenoid assembly on the air intake horn as shown using an existing capscrew. If there is a previously installed assembly for your exhaust brake located on the rear capscrew, it is permissible to install this assembly on the opposite side capscrew. P G. 1

4 3 Locate transfer case vacuum lines adjacent to transmission above starter on driver s side of vehicle (green line = vacuum vent / white line = vacuum source) 4 Locate the main vacuum source. This connection varies between model years. Follow the WHITE line beside the starter up to the firewall cowl to locate the main vacuum source. 5 Remove the existing feed line connected to the main vacuum source. using one of the short hoses and a 3 /16" x 3 /16" barbed coupler (supplied), connect the main vacuum feed (white line) to port #2 of the solenoid valve. P G. 2

5 4 Wheel Drive Vacuum Control System B E F O R E K I T I N S T A L L E D A F T E R K I T I N S T A L L E D Main Vacuum Source Main Vacuum Source White Air Vent Filter Vent Filter Pacbrake Solenoid Indicator Switch Check Valve Green Indicator Switch White Check Valve Green Control Switch on Transfer Case Control Switch on Transfer Case Axle Shift Motor Axle Shift Motor 6 Using the other short line supplied connect vacuum source line to port #1 at the solenoid valve. 7 Using the short hose with breather vent installed, connect to port #3 of the solenoid valve. Route this breather to a location free from water and dirt. 8 Connect the long hose supplied to port #4, and route the other end to the breather from the existing green line. Use the 3 /16" x 3 /16" barbed coupler supplied. Insert one side into the rubber 90º hose end, connect the other side to the hose from port #4. Secure all hoses with the tie-straps provided. P G. 3

6 Dash Switch and Wiring Installation 9 Consult with the vehicle owner for their preference on the location of the ON/OFF switch. Drill a 1 /2" hole to accommodate the switch. Connect the wires to the dash switch (as shown in the schematic at step 10) and install the switch. 10 Locate a 12 volt ignition power source with a 14 to 16 gage wire diameter and connect the T tap terminal. Insert the male terminal of the RED wire into the T tap. Connect the black to a good chassis ground. Route the yellow wire of the harness through the firewall boot into the engine compartment. Recover this wire and route it and connect to the solenoid. Secure with tie-straps provided. Ignition Power Source Vacuum source at firewall Vent line Connect to good chassis ground 10 amp fuse Pacbrake Solenoid Red Yellow Black Low Range On/Off switch Vent line for hub valve Vacuum feed line to hub valve LOW RANGE OFF Check Operation Important! Start the vehicle, engage the transfer case into 4-low and slowly start moving the vehicle forward turning the wheel hard in one direction. The 4WD light should come on and you should feel the front end hop as normal. Stop the vehicle, turn the front wheels straight and engage the 4WD 2 Wheel Low switch, the light should come on in the dash switch. Wait until the 4WD light on the dash goes out, this indicates 2WD. Now slowly start moving the vehicle forward turning the wheel hard in one direction. You should not feel front wheel hop as before. When the low range system is engaged the 4WD light will NOT be on in the dash panel, only the RED light in the low range dash switch will be on. Remember to disengage both the 4WD 2 Wheel Low switch and the 4WD switch or lever to 2WD before driving away. This system is designed for low speed maneuvering when high torque is necessary only. P G. 4

7 Pacbrake s 4WD 2 Wheel Low & Performance Override Switch kits are sold with the following warranty: These Pacbrake kits are warranted to be free of defects in construction and operation under normal use and service for the Warranty Coverage periods set forth below. THERE ARE NO REPRESENTATIONS OR WARRANTIES WHICH EXTEND BEYOND THE TERMS HEREOF: Warranty Coverage: The Warranty for the Pacbrake 4WD 2 Wheel Low and Performance Override Switch kits is 6 months. Under this warranty our factory is obligated to replace, without charge, any part returned to us which our examination discloses to our satisfaction to have been defective within the Warranty Coverage period measured from the date of delivery of the product in question to the original user. This warranty will not apply to any part or parts which have been altered or repaired outside of our factory nor to the parts which have been subjected to misuse, abuse, neglect, or accident, nor to parts which have been improperly applied or installed. Improper installation or application, or substitution of parts not manufactured or approved by us, shall void this warranty. This warranty will not extend to any product/parts other than the Pacbrake supplied items. If the product should become defective within the Warranty Coverage period, an authorized Pacbrake distributor should be notified. If any of the Pacbrake distributors are unable to correct your problem or if you have any questions regarding this warranty, write to the following address giving full details of your problem including the Model and Serial Numbers of the product involved. Pacbrake th Avenue Surrey, B.C., CANADA V4N-4C3 P.O. Box 1822, Blaine, Washington SOLE LIABILITY AND YOUR EXCLUSIVE REMEDY IS LIMITED TO THE OBLIGATIONS SET FORTH HEREIN, AND PACBRAKE SHALL NOT BE LIABLE FOR ANY SPECIAL, INDIRECT OR CONSEQUENTIAL DAMAGES Pacbrake Company toll-free: phone: fax: info@pacbrake.com Internet: Canada: Ave. Surrey BC V4N 4C3 USA: 250 H St. Box 1822 Blaine WA Pacbrake exhaust brakes are protected by law. U.S. patents 5,445,248. Patents pending. Pacbrake and Direct Mount are registered trademarks of Pacbrake Company. Other trademarks used herein are property of their respective holders. Printed in Canada L