OWNERS MANUAL with installation instructions Banks Brake EXHAUST BRAKE SYSTEM 1994-98 Dodge 5.9L Cummins (12-valve) Turbo-Diesel Pickups with Manual Transmissions THIS MANUAL IS FOR USE WITH SYSTEMS 55217 and 55218 Gale Banks Engineering 546 Duggan Avenue Azusa, CA 91702 (626) 969-9600 Fax (626) 334-1743 Product Information & Sales: (800) 438-7693 Customer Support: (888) 839-5600 Installation Support: (888) 839-2700 bankspower.com 2004 GALE BANKS ENGINEERING 02/03/04 PN 96982 v.5.0
General Installation Practices Dear Customer, Your new Banks Brake is a uniquely designed exhaust brake with electronic controls, designed to achieve the optimum level of braking from your vehicle s engine. If you have any questions concerning the installation of the Banks Brake, please call our Technical Service Hotline at (888) 839-2700 between 7:00 am and 5:00 pm (PT). If you have any questions relating to shipping or billing, please contact our Customer Service Department at (888) 839-5600. 1. For ease of installation of your Banks Brake, please read this 16 page Owner s Manual before starting any work. Become thoroughly familiar with all components and phases of the installation before beginning any work. 2. Inspect all components supplied for any foreign material that may have entered during shipping and handling. 3. Pay particular attention to the routing of wires and hoses. Keep them away from exhaust heat, moving parts and sharp edges that may cause cuts or other damage. Route or tie away from critical areas as required. Keep all wires a minimum of 6" from hot exhaust parts, 8" or more is recommended whenever possible. Figure 1 Warning! Never work under any vehicle supported only by a jack of any kind. DO NOT USE concrete blocks or other masonry items that may collapse under the vehicle weight. Thank you. 2 96982 v.5.0
Brake Installation 1. As a precaution, disconnect the ground of the battery (if there is more than one battery, disconnect both). 2. Remove the air-cleaner box assembly (including the black flex hose) from the passenger side of the vehicle. 3. Lift and support the vehicle. 4. If a Banks Stinger, Stinger-Plus or Powerpack is being installed now or is already installed on the vehicle, proceed to Step 6. 5. Underneath the vehicle, locate the bend at the bottom of the turbine outlet pipe. Make a mark at the centerline of the pipe 5 1 4" from the bend tangent line as shown in Figure 1. Using a reciprocating saw or hacksaw, make a straight cut through the pipe at the indicated location. 6. Locate the ball flange at the inlet of the turbine outlet pipe. Using a 13- mm socket, remove the two 10-mm bolts that attach the flange to the turbine outlet casting. 7. Remove the five 8-mm bolts that attach the exhaust elbow to the turbine outlet flange. Remove the elbow and gasket. 8. Underneath the vehicle, remove the upper portion of the turbine outlet pipe. Note: When a Banks system is already installed on the vehicle some heat may be required to expand the tubing and allow the turbine outlet pipe to be removed. 9. Loosely install the new turbine outlet pipe to the existing intermediate pipe. Do not tighten any clamps at this time. 10. Install the Banks Brake assembly onto the outlet of the turbocharger using the five new 8-mm bolts and flat washers provided. See Figure 2. Do not re-use the stock turbine outlet gasket. The fully machined mating surface on the Banks Brake does not require a gasket for adequate sealing. Use the supplied anti-seize compound on the bolts and tighten them evenly. The torque specification for these bolts is 160 in-lbs. Figure 2 96982 v.5.0 3
Figure 3 4 96982 v.5.0
11. Tighten the two 7 16" bolts at the ball flange to 15 ft-lbs. Note: Do not use an impact wrench on these fasteners. The wide span of the two bolt spherical flange creates sufficient clamping force when 15 ftlbs is used. Exceeding this torque specification will not increase the sealing performance. 12. Tighten the exhaust clamp that seals the turbine outlet pipe to the intermediate pipe. 13. Thread the 90-degree hose fittings provided into all three ports of the actuator control valve as shown in Figure 3. Mount the valve to the bracket as shown using the two 4-40 screws, washers and nylock nut assemblies. 14. On the driver s side firewall, there is a large, soft 3 1 2" diameter grommet located under the cowl that allows the vehicle s wiring harness to pass from the cab to the engine compartment. Enlarge the hole approximately 1 2" to allow the Banks Brake wiring harness to pass through. Be careful not to damage the vehicle harness. See Figure 4. 15. Inside the cab, remove the dash kick panel below the steering column by removing the three screws and pulling on the panel. 16. Route the harness through the firewall grommet from inside the cab as shown in Figure 5. 17. Remove the screws and attach the two 1 4" terminals to the throttle switch as shown in Figure 6. 18. To install the throttle switch, locate the stud shown in Figure 6 and remove the nut. 19. Install the throttle switch loosely to the bracket using the two 6-32 screws, washers and backplate as shown in Figure 6. The bracket is slotted to allow adjustment after installation. 20. Install the bracket onto the stud as shown and reinstall the nut. The switch arm should be positioned behind the throttle lever. 21. Adjust the switch by loosening the screws and positioning it to click as the throttle returns to its released Figure 4 96982 v.5.0 5
position. Cycle the throttle and listen for the click sound each time the throttle returns to idle. Caution: Do not bend the switch arm to adjust the switch position. Adjust position only by sliding switch on slotted bracket. 22. Plug the 1 4" female connectors from the Banks Brake Harness to the switch terminals as shown in Figure 6. 23. If your vehicle is equipped with cruise control, locate and cut the white wire with a pink tracer located in the vehicle harness bundle shown in Figure 7. Note: Be sure to cut the correct color wire. There may be a white wire with a red tracer in close proximity to the cruise control wire and may easily be mistaken for the right lead. Crimp the male and female 1 4" spade connectors to each end of the cut wires. Connect the two green wires from the harness to each spade connector. 24. Route the remaining leads along the underside of the cowl lip, toward the previously-mounted Banks Brake Valve Body. 25. Drill a 1 8" pilot hole and mount the actuator control valve to the upper passenger side firewall as shown in Figure 3 using the #12 self-threading screw provided. Note that the ground wire with the ring terminal is installed under the screw head. 26. Connect the red and black wires from the Banks Brake harness to the solenoid valve as shown in Figure 3. 27. Inside the cab, drill one 1 4" hole in the bracket as shown in Figure 5. Mount the black relay provided to the bracket located to the right of the steering column behind the dash trim panel that was removed in Step 15. Use the 1 4-20 bolt and locking nut provided. Figure 5 6 96982 v.5.0
Figure 6 96982 v.5.0 7
Figure 7 Figure 8 8 96982 v.5.0
28. Plug the Banks Brake harness into the relay as shown in Figure 5. Drill a 1 8" pilot hole into lower metal frame under the dash as shown in Figure 5 and install the ground leads from the relay using the #12 sheet metal screw as shown. 29. Install a blue T-tap on the black wire with an orange tracer located in the harness running from the steering column. Attach the black fused power lead as shown in Figure 5. 30. Find an appropriate location for the brake activation switch on the lower dash panel. See Figure 8 for suggested locations. Drill a 1 2" hole through the dash panel in one of Figure 9 these locations. Note that the backside layer of reinforcing material may need to be removed in the area used to mount the activation switch. 31. Attach the three wiring harness leads to the switch assembly per Figure 8. Remove the outer locking ring from the shaft of the switch assembly and install the switch from the back side of the dash panel with the notch in the shaft facing down. Slide the face plate provided over the shaft of the switch to indicate switch position. Thread the locking ring onto the shaft of the switch body. The depth of the switch may be changed by adjusting the location of the back nut on the switch shaft. 32. Secure the wire loom under the dash and hood using the nylon ties provided. Inside the cab, reinstall the dash kick panel removed in Step 15. 33. Find the OEM hose running from the vacuum pump/check valve just foreword of the vehicle power steering pump. Disconnect the 90 degree elbow and install the brass T-fitting as shown in Figure 9. 34. Cut a short length of blue silicone hose (approximately 2") and push it on to the plastic nipple at the end of the factory hard plastic vacuum tube. Attach the other end of the short silicone hose to the T-fitting. 96982 v.5.0 9
Figure 10 35. Re-attach the factory 90-degree elbow to the outlet of the vacuum pump/check valve. Secure all connections with supplied spring band clamps. 36. Use the remaining length of blue silicone hose to connect the vacuum supply to the actuator control valve and actuator. Run a length of hose from the brass 1 4" T-fitting up to the factory vacuum manifold on the firewall and across the cowl area to the previously installed actuator control valve. 37. Attach the vacuum source line to the port on the valve labeled #1. From the port labeled #2, run a length of blue silicone hose to the exhaust brake actuator. See Figure 10. 38. Assemble the black vent hose as shown and attach this line to the port labeled #3. Run this line behind the exhaust brake assembly and secure to a convenient location. Be sure the bronze filter is facing down so any collected moisture will be drained. Secure all vacuum lines with spring band clamps as shown. See Figure 10. 39. Secure all vacuum lines under the hood using the nylon ties provided. Use care to avoid pinching the hose closed. 10 96982 v.5.0
Exhaust Valve Spring Removal/Installation Your Banks Brake is designed to provide the maximum retarding force possible from your engine. This will require the installation of heavy-duty exhaust valve springs designed to work with the increased backpressure created by the Banks Brake system. CAUTION: Exhaust valve spring replacement requires a thorough understanding of engine/valve train assembly and operation. If you do not feel you are qualified to complete this work, have the exhaust valve springs changed by a Banks dealer or a qualified Cummins Service Center. A valve spring compressor and crankshaft barring tool are required for valve spring replacement. These can be purchased from Gale Banks Engineering (part number 97005). WARNING! Never work under any vehicle supported only by a jack of any kind. DO NOT USE concrete blocks or other masonry items that may collapse under the vehicle weight. 1. Disconnect the battery negative cables. 2. Remove the airbox assembly from the passenger side of the engine compartment (including black flexible hose) 3. Underneath the vehicle, remove the black plastic access plug located on the lower passenger side of the transmission adapter housing. See Figure 11. 4. Install a crankshaft barring tool as shown in Figure 11. This tool allows the engine to be rotated using a 1 2" socket wrench with extensions. 5. Remove the valve cover over the foreword most cylinder. 6. Rotate the engine by turning the crankshaft barring tool clockwise until the piston is at top dead center with both valves closed on the compression stroke. This will allow the exhaust valve spring to be removed while the valve is retained by the piston. 7. The piston will be near bottom dead center when you see the intake valve open and then close completely. Continue rotating passed this point until both rocker arms are no longer under compressive force and the piston is at top dead center. 8. Confirm that the piston is at top dead center by twisting the valve pushrods by hand. If you are able to slightly twist each pushrod, the piston is at top dead center and both valve springs are not compressed. 9. There will be two bolts securing the rocker cover stand. Using a 13- mm socket, remove the smaller bolt. Using an 18-mm socket, remove the large bolt. 10. Carefully remove the rocker stand assembly. Do not remove the pushrods and ensure that the pushrods do not become dislodged from the lifters during rocker stand removal. 11. Cover the holes surrounding the pushrods with a rag to avoid dropping foreign matter into the crankcase. 12. Install a valve spring compressor tool as shown in Figure 12 on the exhaust valve spring. Use the compressor to compress 4-5 coils. 13. Without removing the valve spring compressor, continue to slowly rotate the engine using the crankshaft barring tool. When the piston contacts the valve head, you will see the valve start to rise slightly. This will ensure that the valve will not drop into the cylinder bore when the valve spring and keepers are removed. 14. Using a soft rubber mallet, tap on the top of the valve spring compressor slightly to dislodge the valve stem keepers. Remove the two keepers using a magnet. 96982 v.5.0 11
Figure 11 Figure 12 12 96982 v.5.0
15. Remove the valve spring and valve spring compressor tool from the valve stem. 16. Carefully, release the compression on the spring and remove the spring from the tool. 17. Install a new exhaust valve spring into the tool and compress the spring using the same procedure outlined in Step 12. 18. Install the new valve spring over the stem and ensure that the spring is seated securely. 19. With the spring still compressed, install the valve stem keepers removed in Step 14. 20. Carefully release the compression on the spring by rotating the tool handle counter clockwise. Remove the compressor. 21. Verify that the valve stem keepers are fully seated by tapping on the valve stem with a plastic hammer. 22. Reinstall the rocker stand assembly ensuring that both pushrods engage the rocker arms correctly. Torque the smaller bolt to 18 ft-lbs. Torque the larger bolt to 89 ft-lbs then tighten it an additional 90 degrees. 23. Install the rocker cover and tighten the bolt to 18 ft-lbs. 24. Repeat Steps 6 through 22 for the next cylinder toward the back of the engine. Continue until all 6 exhaust valve springs have been replaced. For the two rear cylinders where clearance is limited, remove the plastic handle from the valve spring compressor and rotate the shaft with a wrench. Testing It is essential that the following test be performed before you test-drive your vehicle. Start the engine and turn the power switch to the ON position. Depress the accelerator pedal to bring the engine speed to approximately 1200 RPM. This should cause the Banks Brake to disengage. Releasing the accelerator pedal should cause the Brake to reactivate. Once the preceding test has been successfully completed, the vehicle is ready for a test drive. Test Drive This exercise is to ensure that your vehicle s cruise control will disengage properly after the installation of the Banks Brake. While driving, turn the cruise control on and set it at a safe speed for the conditions. Next, turn the power switch for the Brake to the ON position. This should disengage the cruise control. Now, turn the power switch for the Brake to the OFF position and activate the cruise control again. This time press down on the vehicle s brake pedal to ensure that cruise disengages. Once the test drive has been successfully performed, product installation is complete. Safety Caution: Your Banks Brake is not a substitute for the hydraulic brakes on your vehicle. The device will not correct or compensate for improperly maintained hydraulic brakes. Also please be aware that your Banks Brake is not designed to be used as a parking brake or to bring your vehicle to a complete stop. Your Banks Brake is a supplementary braking system designed to help you slow down or to assist you in maintaining a more constant speed when descending a grade. Remember that the exhaust brake is first and foremost a safety device and is most efficient when used to prevent, rather than correct an over-speed condition. Operation/ Driving Tips Use your Banks Brake to assist in slowing your vehicle while traveling down grades. To activate the brake, turn the switch to the ON position. With the switch on, the brake will be active anytime that your foot is not on the accelerator pedal. Note that cruise control will be cancelled if it is active at the time the Banks Brake is engaged. When alternating between braking activity and acceleration, it is good practice to allow a minimum of one second to elapse after the brake has been disabled or the throttle is applied before reaching full throttle acceleration. This allows enough time 96982 v.5.0 13
1 Exhaust Brake Assembly 2 Wire Harness 3 Fuse, 15A 4 Turbine Outlet Pipe 5 Relay 6 Actuator Control Valve 7 Valve Bracket 8 Valve Filter 9 Nylon Ties (15) 10 1 4" Ultra Fast Tab 11 1 4" Ultra Fast Receptacle 12 Blue Tee-Tap (2) 13 Switch 14 Cover Plate 15 Throttle Switch 16 Switch Bracket 17 Back Plate 18 6-32 Bolt (2) 19 #6 Flat Washer (2) 20 1 4" Terminals (2) 21 1 4" -20 Hex Nylock 22 1 4" -20 x 3 4" Hex Bolt 23 5 16" AN Washer (5) 24 7 16" SAE Washer (2) 25 7 16-17 x 2" Stainless Bolt (2) 26 8mm x 25mm Long Bolt (4) 27 8mm x 40mm Long Bolt (1) 28 4-40 Nylock Nut (2) 29 #12 x 3 4" Long Sheet Metal Screw 30 4-40 Screw x.875" Long (2) 31 Exhaust Clamp 32 Fitting 90 Degree 1 8" NPT x 3 16" Hose Barb (4) 33 T-Fitting 1 4" Hose Barb 34 Coupler 1 8" NPT 35 Spring Band Clamp (9) 36 Silicone Hose, Blue 37 #4 SAE Washers (2) 14 96982 v.5.0
Banks Brake, General Assembly 96982 v.5.0 15
for the brake valve to fully open and eliminates the possibility of excess exhaust back pressure being introduced into the engine. If your vehicle is equipped with an automatic transmission, your Banks Brake can be used with the transmission in overdrive or 3rd gear. To increase the overall effectiveness of the Banks Brake, you may back shift from overdrive to 3rd gear to increase engine RPM. If your vehicle is equipped with a manual transmission, you can also down shift to maintain peak retarding force. Maintenance To increase the longevity of your Banks Brake and maintain it to a high level of efficiency, we strongly recommend that it be used once daily. If the vehicle is not driven daily, please use the brake once each time the vehicle is driven. Gale Banks Engineering 546 Duggan Avenue Azusa, CA 91702 (626) 969-9600 Fax (626) 334-1743 Product Information & Sales: (800) 438-7693 Customer Support: (888) 839-5600 Installation Support: (888) 839-2700 bankspower.com 16 96982 v.5.0