HIGH PERFORMANCE PRXB EXHAUST BRAKE C44059, C4406, C44063, C44065 APPLICATION 994-2002 DODGE RAM AUTOMATIC TRUCKS EQUIPPED WITH 47RE TRANSMISSIONS WITH 5.9L, 24 VALVE CUMMINS DIESEL ENGINES
GETTING STARTED Thank you and congratulations on your purchase of a exhaust retarder. Before starting the installation, please read the entire installation manual carefully and be sure you have a full understanding of the installation. Check that your kit is correct for the application and contains all the necessary parts. C44059 Kit is a high performance PRXB exhaust brake designed to provide maximum retarding throughout the RPM range of your 994-995 Dodge 2 valve Cummins with an automatic 47RH transmission. Heavy duty exhaust valve springs ARE MANDATORY for all 2 valve engines. C400 Spring Kit is included in the C44059 Kit. Failure to install the heavy duty springs WILL result in engine damage! C4406 Kit is a high performance PRXB exhaust brake designed to provide maximum retarding throughout the RPM range of your 996-998 Dodge 2 valve Cummins with an automatic 47RE transmission. Heavy duty exhaust valve springs ARE MANDATORY for all 2 valve engines. C400 Spring Kit is included in the C4406 Kit. Failure to install the heavy duty springs WILL result in engine damage! C44063 Kit is a high performance PRXB exhaust brake designed to provide maximum retarding throughout the RPM range of your 998½ Dodge 24 valve Cummins with an automatic 47RE transmission. Installation of heavy duty exhaust valve springs is not required on 24 valve engines. C44065 Kit is a high performance PRXB exhaust brake designed to provide maximum retarding throughout the RPM range of your 999-2002 Dodge 24 valve Cummins with an automatic 47RE transmission. Installation of heavy duty exhaust valve springs is not required on 24 valve engines. ADDITIONAL MOUNTING GROUP REQUIRED Vehicles with aftermarket exhaust systems require a different mounting group. - Vehicles with a 3" factory downpipe and an HX 35 turbo, use Part # C430 - Vehicles with a 4" aftermarket exhaust and a 5 bolt HX 35 turbo outlet, use Part # C43 - Vehicles with a 4" aftermarket exhaust and an HX 40 or equivalent turbo with a half marmon flange, use Part # C432 PG
C44059, C4406, C44063 & C44065 ELECTRICAL INSTALLATION Remove the lower dash panel and locate an ignition power supply at the base of the steering column. 994-997 models use a medium blue 4 gage wire and blue T tap 998-2002 models use a black with orange tracer 8 gage wire and a red T tap. Check the wire with a voltmeter to ensure it is 2 volts and an ignition power source. Attach the supplied T tap to this wire and insert the red 6 gage 3 amp fused wire to this T tap. 2 Mount the control unit to the provided bracket on the inside of the firewall (under the dash - as shown in the photo) using the factory stud and nut for the steering column. Once the control unit is fastened to the stud, connect the grey and black connectors of the harness to the control unit. 2 Secure the harness with the provided tie-straps. 3 Locate the plastic plate in the drivers side of the firewall. Drill a hole large enough to feed the harness through. Then, feed the harness into the engine compartment from the cab side. Apply silicon sealant around the loom to provide a seal. 3 4 ON/OFF SWITCH INSTALLATION: ALL KITS Provided on the last pages of this manual are 2 templates for dash switch locations. The 2 switch locations are suggestions only for specific years. Consult the customer for their preference before drilling a ¼" hole to accommodate the dash switch. 4 Install the dash switch and route the wires to the control unit. Secure the wires with the supplied tie-straps. At the control unit, locate the matching wire colors and connect them using the supplied heat shrinkable red butt connectors. Once crimped, heat the connector to provide a water tight seal. Re-install the lower dash panel. PG 2
5 Route the black wire with the eye terminal to the negative battery terminal or a good chassis ground. Secure with the supplied tiestraps. 5 Remove both the positive battery terminals. Route the red fused wire with the eye terminal to the positive battery terminal (leaving the positive lead disconnected). The battery leads are connected in step 2. 6 Route the remaining harness along the firewall to the passen gerside and then route it forward along the fender to the pas senger side battery. Make sure it is secured away from heat sources and moving parts using the supplied tie-straps. C44063 & C44065 kits proceed to step 8. Powertrain Control Module C2 (Diesel) Transmission Solen (5.9L 6 7 THROTTLE SWITCH INSTALLATION: C44059 & C4406 KITS ONLY Locate the stud shown in the photo and remove the nut. Install the switch assembly with the switch arm horizontal. Re-install the stud nut and tighten, making sure the switch arm is behind the accelerator lever. Adjust the switch by loosening the screws and positioning it to click just as the throttle returns to its released position. Cycle the throttle and listen for the click each time the throttle returns to idle. Tighten the screws when adjustment is complete. Locate the black and white wires of the harness originating at the control unit. Attach the black wire to the terminal connected to the diode on the throttle switch. Connect the white wire to the other terminal on the throttle switch. Make sure it is secured away from heat and moving parts using the supplied tie-straps. Consult the wiring schematic pertaining to your kit #, found on page 0-2. 7 PG 3
C44063/C44065 0 PCM AND TRANSMISSION CONNECTIONS Route the remaining harness along the fire wall to the passenger 8 side C44063 and then & route C44065 it down KITS to and ONLY: along the passenger side frame rail. Under Make sure the hood, it is secured beside with the the fuel supplied filter, locate tie straps the and factory is not 3 pin compromised Weather- Pac by heat connector or moving on parts. the driver side of the engine (shown by the arrow). Remove the protective cap and install the mating Consult connector with customer in the for their preferred harness. location Install to the mount removed the protective quick cap connector the unused for the air connector line. Using on the the two self tapping harness screws - unless mount you the have L-bracket. a performance Insert the module bulkhead connected airline fitting to into it. If the so, it connects L-bracket to the and tighten connector. the jam nut to secure it. Follow the airline installation NOTE: Some procedures 999 in model the next year step. trucks and all 998½ will require the use of a 3 pin triangular jumper harness to connect to the data Air link System connector. Installation: See schematic pertaining to your kit #, found on page 0-2. Proceed to step 0. PRESSURE SWITCH 9 C4406 KIT ONLY: Locate the diagnostic connector under the dash on the drivers side. Connect the male plug of the harness to the factory diag - nostic connector. Secure 6' LONG the # 2 # connector to the diagnostic 9' LONG connector using the supplied tie straps. CYL IN AIR Consult with COMPRESSOR custom for their preferred AIR INTAKE l TANK to access the conn 0 C4406, C44063 & C44065 Remove the air filter housing to SOLENOID access the passenger side firewall 9' LONG AIR EXHAUST BRAKE VALVE and locate the PCM (shown in fig 0B). Remove the C2 and C3 con- COMPRESSOR COMPRES nectors. Remove the plastic cover to access the wires. Pull back the 8' LONG conduit to give access for attaching wires into the factory harness. AIR Use fig 0BB as a guide to the pin locations. COMPRE 0 Cut the nylon airline provided to the lengths shown in this diagram. Make sure the nylon airline is cut square on each end and is B pushed C2 CONNECTIONS into the fittings until it clicks Locate the orange/black wire in pin of the C2 connector. Cut this wire. Attach the brown wire of the harness to the PCM side. n airline is cut square on each end and is Attach the orange wire to the harness side of the orange/black wire. On the passenger side frame rail, locate the section of the inner frame These with connections a cut out. The are air solenoid, done using with the the supplied exhaust port red pointing heat shrinkable butt connectors. down, mounts inside this cut out and is secured to the frame with one Locate of the air the tank brown fasteners wire in (see pin step 22). of the Route C2 the connector. Cut this wire and harness splice to the this blue location wire and of the connect the Weather-Pac harness into connectors. it using the supplied red heat shrinkable butt connectors. Quick F for 25 curly hose k 8 Quick Fitting for 25 curly hose kit. Consult with customer for their preferred location to access the connector 9 0 BB 2 C3 CONNECTIONS Locate the orange/white wire in pin 3 of the C3 connector. Cut this wire and splice the yellow wire of the harness into it using the supplied red heat shrinkable butt connectors. Install the fittings and pressure switch in the top of the tank as shown Using the the photo. heat gun, Use thread heat the sealant connectors all fittings to provide to prevent a water air tight seal leaks. on The all heat air tank shrinkable requires butt 2-5 /6" connectors. holes a 3 See /4" center. the wiring Use one diagram pertaining of the pre-existing to your holes kit #, in found the frame on page and drill 0-2. the second hole. Using the fasteners provided, mount the air tank on the outside of the frame and the solenoid on the inside using the same fastener. Install the nylon airlines to the solenoid valve and air tank as shown in step 0. Connect the Weather-Pac connector of the harness to the pressure switch connector. PG 4
a C44059 KITS ONLY: Route the brown, orange, blue, yellow and the OBD connector of the harness along the firewall to the passenger side firewall. Locate the factory OBD connector and apply electrical tape to secure them together. Remove the air filter housing to gain access to the PCM. A b C44059 KITS ONLY: On the passenger side firewall, locate the PCM (shown in fig B). Remove the connector by loosening the bolt in the center. Remove the plastic cover to access the wires. Pull back the conduit to give access for attaching wires into the factory harness. Use fig BB as a guide to the pin locations. Locate the orange/black wire in pin 54 of the PCM connector. Cut this wire. Attach the brown wire of the harness to the PCM side. Attach the orange wire to the harness side of the orange/black wire. These connections are done using the supplied red heat shrinkable butt connectors. Locate the brown wire in pin 55. Cut this wire and splice the blue wire of the harness into it using the supplied red heat shrinkable butt connectors. B BB Locate the orange/white wire in pin 0. Cut this wire and splice the yellow wire of the harness into it using the supplied red heat shrinkable butt connectors. See wiring diagram pertaining to your kit #, found on page 0-2. view shown is of the PCM side, connector removed. 2 Consult with the customer for their preferred location to mount the quick disconnect for the airline. The mounting location should be in a clean, dry area with easy access to the operator. 2 Using the two self tapping screws mount the L bracket. Insert the bulkhead airline fitting into the L bracket and tighten the jam nut to secure it. Apply thread sealant to prevent air leaks. Follow the airline installation procedures in the next step. in-lb PG 5
3 Shown in the photo is a suggested location marked A. Connect one end of the remaining air line into the quick connect assembly and route this to the remaining fitting at the compressor. Mount the air inlet filter in a cool, dry location. A suggested location is shown in photo, marked with a B. Locate the blue nylon airline provided and route to the filter housing. Route the other end to the compressor inlet fitting located on the compressor body (the compressor is installed in next step). Make sure the nylon hose is cut square on each end and is pushed into the fittings until it clicks. B A 4 Remove the passenger side battery. Place the compressor and bracket assembly into the battery box as shown in the photo. Place and secure the battery on top of the compressor bracket. Reinstall the hold down assembly. Connect the corresponding weather pac connectors of the harness to the compressor. Do not connect the battery cables at this time. 5 Install the 90 fitting in the top of the tank and the provided hex plug (or drain valve if desired) into the bottom, as shown in the photo. Use thread sealant on all fittings to prevent air leaks. The air tank requires 2-5 /6" holes on a 3¼" center. For fastening to the frame, use one of the pre-existing holes in the frame and drill the second hole. Using the fasteners provided, mount the air tank on the outside of the frame. Connect the nylon airline to the air tank and route the other end to the fitting at the solenoid (shown in the photo below) and connect. PG 6
6 Compressor and Airline Routing Connect to quick connect Connect to air intake filter Connect to air tank Connect to exhaust brake 7 Exhaust Brake Installation All vehicles, remove the two capscrews that attaches the cast elbow to the header pipe. 994-998 vehicles, remove the V clamp between the elbow and the turbo charger. Remove the cast elbow. Removal of the 5 bolt flange is not required. 999-2002 vehicles, remove the 5 capscrews securing the elbow to the turbocharger. Remove the cast elbow. NOTE: 2 valve engines REQUIRE H.D. exhaust valve springs to be installed. Contact Customer Service @ 800.663.0096 for installation procedure, if required. PG 7
8 From below the vehicle, remove the header pipe by removing the exhaust clamp at the header pipe connection to the intermediate pipe. Once the header pipe is removed from the vehicle, loosely install the elbow back onto the header pipe. Loosely assemble the to the adapters for measuring purposes. Lay the two assemblies side by side to determine the correct location to cut the header pipe. The adapter is expanded to fit over the header pipe, consider this in your measurement. Cut the pipe to length. 9 999-2002 vehicles, at the turbocharger check the gasket surface for imperfections. If okay, install the new gasket and turbo flange provided. Replace the 5 capscrews removed earlier. Torque the capscrews to 0 in-lbs in a star pattern, then retorque to 220 in-lbs in a star pattern. After a road test, retorque to 220 in-lbs. in-lbs in-lbs 20 Install the as an assembly (exhaust brake and both exhaust adapters). The exhaust brake cylinder must be on the bottom to attain correct clearances. Do not fully tighten the turbo V clamp, as adjustment may be necessary. Install the shortened header pipe into the rear flange and intermediate exhaust pipe. Adjust the assembly to attain maximum clearance and a good pipe fit. Torque the turbo V clamp to 6 ft-lbs and then the exhaust brake pressure side V clamp to 2 ft-lbs. Tack weld the rear adapter to the header pipe and remove the V clamp and header pipe for welding. Reinstall the header pipe and torque the V clamp to 2 ft-lbs. 2 Using the nylon airline provided connect the solenoid valve port marked CYL to the air cylinder. (Fitting installed in step 26) Reconnect both positive battery terminals with the positive lead of the harness. Reconnect both negative battery terminals. Connect the black wire ( ground) to the negative battery terminal. Secure all electrical harnesses and nylon airlines with the supplied tie-straps. PG 8
TESTING THE SYSTEM - C44059, C4406, C44063 & C44065 With the switch in the OFF position, start the engine and allow to idle. The compressor should pump air for approximately 2 minutes (this will fill the air tank from empty). Once the control unit confirms the air tank has reached maximum air pressure, the control unit will perform a Self Test Cycle which will activate and release the exhaust brake two times with the vehicle stationary. Vehicles with 47RH/RE transmissions which have aftermarket valve bodies and aftermarket lock-up torque converters which are able to hold lock-up during exhaust braking in st and 2nd gears can use the later 48RE programming. To change the existing program within the control unit, simply locate the orange wire with a spade connection approximately 6 inches from the control unit. Disconnect this connection. Turn the ignition ON. The exhaust brake should cycle 3 times confirming the 48RE program has been loaded. This difference between the two programs is that the 48RE transmission will allow exhaust braking in 2nd and st gears, where the factory 47RH/RE transmission will not. Test drive the vehicle. If lock-up will not hold during exhaust braking in 2nd or st gear, re-connect the orange wire. LED SWITCH OPERATION RED - Brake enabled and ready for activation GREEN - Parameters are achieved, and the controller is now commanding torque converter lock-up ORANGE - Brake currently active No Illumination - Brake disabled/off FEATURES - C44059, C4406 & C44065 The control unit has a built in warm-up feature. This feature will activate the exhaust brake at idle with the vehicle stationary when the switch is turned ON. When the coolant temperature reaches 70 F or 75 C, the control unit will disable the warm-up feature at idle. When performing a road test, the O.D. (overdrive) switch must be in the OFF position and the switch in the ON position. Attain road speed above 40 MPH or 65km/h and release the accelerator pedal. The exhaust brake should apply, slowing the vehicle. Once the exhaust brake has brought the vehicle s engine speed below 900 RPM, the exhaust brake will disengage. When using the auxiliary coil hose for inflation, the switch must be turned ON with the engine running. PG 9
electrical schematic: c44073 994-995 2 VALVE ENGINEs, AUTOMATIC transmission ONLY Exhaust brake Control Unit O BD I Plug Purple 2 4 60 40 20 POWERTRAIN CONTROL MODULE White PIN 55 PIN 54 PIN 0 Cut Here Pin 2 Pin Brown / 8 6 7 5 Br o wn 4 2 3 Transmission Soleniod Pin 5 Pin 6 White Pin 22 Brown /White /White Throttle Ignition Power Source Diode Splice To Quick Connect 3 Amp Fuse Pin 4 Yellow Yellow Pin 2 Pin 9 Pin 0 Pin 4 Pin 5 Pin 6 Pin 9 Pin 24 Pin 23 Pin 8 Grey Pin 3 A B Pressure Air Inlet Port To Battery (negative) Solenoid To Cylinder To Air Tank 30 Amp Inline Fuse Compressor Grey Driver s Side Battery + Pos. Neg. - PG 0
i INSTALLATION MANUAL - C44059 - INSERT / C4406 TITLE / HERE, C44063 L234 / C44065, L5855 electrical schematic: c44076 996-998 2 VALVE ENGINEs, AUTOMATIC transmission ONLY Exhaust brake Control Unit 22 2 Purple OBD II Plug Powertrain Control Module C2 (Diesel) Powertrain Control Module C3 (Diesel) White Brown 32 2 Pin 5 Pin 7 Splice Pin 2 Pin Cut Here Ignition Power Source Brown Brown / with White Wire 7 8 6 5 4 2 3 Pin 4 Transmission Soleniod Splice Green Yellow Pin5 3 Amp Fuse Pin6 White Pin 4 Yellow Pin22 Pin 2 Pin 8 Pin 7 Pin5 with White Wire Pin6 Pin9 P 24 n Pin 23 Pin8 Grey Pin 3 A B 22 2 32 2 Throttle Diode PIN3 To Quick Connect Pressure Air Inlet Port To Battery (negative) Solenoid To Cylinder 30 Amp Inline Fuse Compressor To Air Tank Grey Driver s Side Battery + Pos. Neg. - PG
electrical schematic: c44075 998½ - 2002 24 VALVE ENGINEs, automatic transmission ONLY Exhaust brake Control Unit Purple White Pin 2 Pin Pin 4 Pin 2 A B Jumper for 98½- 99 Model Year Trucks 22 2 Module C2 (Diesel) Powertrain Control 32 2 Brown Cut Here / Splice Diagnostic 3 Amp Fuse Ignition Power Source Brown Pin5 Pin6 Pin 7 8 6 7 5 4 2 3 Pin B Pin A Transmission Soleniod Green Yellow Pin22 Pin 4 Pin Pin2 Pin 5 Pin 24 Pin 9 Pin 23 Pin8 Grey Pin 3 22 2 32 2 Pin 3 with White Tracer Splice with White Tracer Yellow Module C3 (Diesel) Powertrain Control To Quick Connect Pressure Air Inlet Port 30 Amp Inline Fuse Compressor To Battery (negative) Solenoid To Cylinder Grey Driver s Side Battery + Pos. To Air Tank Neg. - PG 2 L5855_REV8.07.04.20
DASH SWITCH TEMPLATE 994-998 Flush with with center center of screw of screw hole hole DODGE RAM DASH S WITCH TEMPLATE MODEL YEARS 994-998 /2" Dril For C44072 and C44074 kits NOT using a shifter switch /4" Drill - For C44073, C44059, C44075 C4406 and C44063 C44076 and kitsc44065 kits Cut Cut out out templ template ate along along outer outer edge edge d an and align align as as shown. shown Flush with edge edge of of panel panel Hood release handle cut-ou t Hood release handle cut-out
DASH SWITCH TEMPLATE 999-2002 Align with bottom of dash bezel Cigarette Lighter NOTE: Template location is only a suggestion. Access to back of this location is difficult NOTE: and Template wires location must isbe installed only a suggestion on switch. Access terminals to back of this loc ation is prior difficult to installation. and wires must be installed on switch terminals prior to install ation. Cut out template Cut out templ along ate along outer outer edge edge and and align align as as own. sh shown * Alternate Location At Bottom Of Page /2" Drill For C44072 and C44074 kits NOT using a shifter switch /4" Drill /4" Drill For C44073, C44075 For C44059, and C44076 C4406, kits C44063 and C44065 kits Flush with edge of panel /2" Drill or /4" Drill