BD VALVE BODY

28 November 2006
ValveBody #1030418 / 1030419
1
BD VALVE BODY
For 2000-2004 Dodge 5.9L 24V Cummins Trucks
-- Installation Instructions -1030418
1030419
2000-2002 Dodge 24V
47RE
2003-2004 Dodge 24V
47RE/48RE
PLEASE READ ALL INSTRUCTIONS BEFORE INSTALLATION
BD Engine Brake, Inc.
Plant Address: Unit A10, 33733 King Rd, Abbotsford, BC, Canada V2S 7M9
U.S. Shipping Address: 88-446 Harrison St, Sumas, WA 98295 U.S. Mailing Address: P.O. Box 231, Sumas, WA 98295
Phone: 604-853-6096 Fax: 604-853-8749 Internet: www.bd-power.com
28 November 2006
ValveBody #1030418 / 1030419
2
Tools Required
•
•
•
•
•
•
•
Inch Pound Torque Wrench
3/8” or 1/2" drive socket sets including 11mm & 13mm sockets
#25 Torx Bit
Combination Wrench Set including 7/16” & 3/4”
3/16” Allen wrench
High quality pressure gauge (0-160psi)
Voltmeter
Additional Parts Required (Not included)
• ATF+3 Transmission Fluid
• 2 Bottles of Red Lube Guard (recommended)
Installation Notes
All Diesel Rams should be tested prior to engine or transmission performance tuning.
Check transmission oil level prior to all work. Pressure testing will produce test results
that can help to determine the ability of the transmission to prevent the clutch surfaces
from slipping. Slippage will result in premature converter and transmission wearing
characteristics (soft or severe shifting, high transmission temperature).
2800-3000RPM (Wide Open Throttle)
With the transmission at operating
temperature, ensure that the shift points are
correct before recording pressures.
47RE Transmissions
Transmission Line Pressure
OEM Pressure
BD Pressure
Transmission in DRIVE w/Engine at
idle
55-65psi
70-75psi
Transmission in DRIVE w/Convertor
Locked up @ 1800 - 1900 rpm
64-72psi
84-94psi
Test #1
Test #2
Test #1
Test #2
48RE Transmissions
Transmission Line Pressure
OEM Pressure
BD Pressure
Transmission in DRIVE w/Engine at
idle
55-65psi
70-75psi
Transmission in DRIVE w/Convertor
Locked up at 1800 - 1900 rpm
85-95psi
95-105psi
BD Engine Brake, Inc.
Plant Address: Unit A10, 33733 King Rd, Abbotsford, BC, Canada V2S 7M9
U.S. Shipping Address: 88-446 Harrison St, Sumas, WA 98295 U.S. Mailing Address: P.O. Box 231, Sumas, WA 98295
Phone: 604-853-6096 Fax: 604-853-8749 Internet: www.bd-power.com
28 November 2006
ValveBody #1030418 / 1030419
3
Transmission Shift Points
Transmission Shift Point (RPM)
Before
After
2nd – 3rd Shift point (Normal Driving)
2nd – 3rd Shift point (Wide Open Throttle)
IMPORTANT – IF PRESSURES AND/OR SHIFT POINTS ARE NOT TO SPECS, THE
TRANSMISSION MUST BE REPAIRED OR SERVICED BEFORE MODIFICATIONS.
Pressure Testing
1. Pressure testing is accomplished by inserting a fitting and hose assembly with a
good quality gauge into the center 1/8” port on the passenger side of the
transmission. Leave the gauge attached for testing later.
2. VERY IMPORTANT – Road test with the pressure gauge in place and record
pressures and shift point RPM’s BEFORE modifications are carried out to
determine the condition of the transmission prior to installing this valve body.
Pressure will only be indicated with the transmission in “Drive”.
3. Secure the vehicle with wheel chocks and place the transmission in Neutral.
4. Ensure the valve body has not been damaged in shipping and it is the proper part
number for your vehicle.
5. Starting at the transmission,
remove the kick down lever and
spring.
6. Rotate the shift lever to the rear of
the
vehicle
to
place
the
transmission in the PARK position.
BD Engine Brake, Inc.
Plant Address: Unit A10, 33733 King Rd, Abbotsford, BC, Canada V2S 7M9
U.S. Shipping Address: 88-446 Harrison St, Sumas, WA 98295 U.S. Mailing Address: P.O. Box 231, Sumas, WA 98295
Phone: 604-853-6096 Fax: 604-853-8749 Internet: www.bd-power.com
28 November 2006
ValveBody #1030418 / 1030419
4
7. Loosen the shift lever bolt then rotate
the lever towards the front of the
truck shifting the transmission into 1st
/ LOW position. This allows for the
removal of the Park Rod E-clip
without dropping the valve body.
Remove shift lever.
8. Disconnect the wiring connectors
from the Neutral Safety switch and
Valve Body then remove the Neutral
Safety switch from the transmission.
9. Install a large drain pan under the transmission, remove the oil pan, drain the
transmission oil and remove the filter.
10. Carefully remove the E-clip from the park rod, leaving the park rod in the
transmission.
11. Remove the 10 valve body bolts, remembering the location of the different bolts.
The bolts are different lengths and MUST be re-installed in the proper location.
12. When lowering the valve body, gently
work it around so that the park rod
lever is left in the transmission and
ensure that the electrical plug is not
damaged in the removal process.
13. CAUTION - As you lower the valve
body, watch for the accumulator
piston and spring falling out.
BD Engine Brake, Inc.
Plant Address: Unit A10, 33733 King Rd, Abbotsford, BC, Canada V2S 7M9
U.S. Shipping Address: 88-446 Harrison St, Sumas, WA 98295 U.S. Mailing Address: P.O. Box 231, Sumas, WA 98295
Phone: 604-853-6096 Fax: 604-853-8749 Internet: www.bd-power.com
28 November 2006
ValveBody #1030418 / 1030419
nd
5
14. This is the time to change the 2 gear band strut to the heavy duty one we supply.
First loosen the band adjusting screw lock nut with a ¾” wrench, and then unscrew
the adjuster until the stock strut can be removed.
Stock Band Strut in place
New BD Band Strut in place
15. Install the new BD strut with tapered side down, towards the pan, and center in the
guides. Torque the band adjustment to 72 lbs-in., then back out 1 7/8 turns and
tighten lock nut. The round end of the enclosed micro-hockey stick tool can also be
used as a feeler gauge to set the front band adjustment.
16. From the old valve body, remove the
electrical solenoid and sensor and
install them on the new BD Valve
Body.
17. IMPORTANT - Before installing the BD
Valve Body, lubricate the manualshifting shaft and the O-ring on the
electrical connector that fits into the
transmission case. Rotate the shift
lever all the way forward to place the
valve body into 1st / Low gear position
so that the park rod and E-clip can be
attached later.
BD Engine Brake, Inc.
Plant Address: Unit A10, 33733 King Rd, Abbotsford, BC, Canada V2S 7M9
U.S. Shipping Address: 88-446 Harrison St, Sumas, WA 98295 U.S. Mailing Address: P.O. Box 231, Sumas, WA 98295
Phone: 604-853-6096 Fax: 604-853-8749 Internet: www.bd-power.com
28 November 2006
ValveBody #1030418 / 1030419
6
18. Place the accumulator piston and
spring into the BD Valve Body. If you
cannot balance these parts on the valve
body, hold them in place with a
supporting tool or wire until the Valve
Body is installed.
19. Once the valve body is in position,
insert the park rod into the manual shift
lever and hold the valve body in place
with a couple of bolts.
20. Install the E-clip on the park rod using
the flat, slotted end of the Canadian
micro-hockey stick.
“Hockey Stick” Tool
21. Install the valve body mounting bolts, ensuring that the varying length bolts are
installed into the proper positions, and then torque evenly to 10 lbs-ft.
22. Install the manual lever on the outside of the transmission and check for full
movement of the detent shift. There must be 5 distinct positions that are felt from
Low (1st) to Park. Leave the transmission in the neutral position and tighten the
retaining bolt. Re-install the kick lever and spring.
23. Install the neutral safety switch and adjust as required, and then tighten. The reverse
lights at the rear of vehicle should illuminate when the shift lever is in the reverse
position (key on).
BD Engine Brake, Inc.
Plant Address: Unit A10, 33733 King Rd, Abbotsford, BC, Canada V2S 7M9
U.S. Shipping Address: 88-446 Harrison St, Sumas, WA 98295 U.S. Mailing Address: P.O. Box 231, Sumas, WA 98295
Phone: 604-853-6096 Fax: 604-853-8749 Internet: www.bd-power.com
28 November 2006
ValveBody #1030418 / 1030419
7
24. Install the new filter on the valve body using 3 screws, instead of the 2 that the OEM
filter was attached with (stock on the 97-00 trucks).
25. We suggest that you install either a drain plug in the original oil pan or, even better,
install a BD HD oil pan, which has extra oil capacity, cooling fins, a magnetic drain
plug, and adds strength to the transmission case to prevent flexing.
26. Install the shift linkage to the manual lever on the transmission using the wave
washer and hitch pin. Tighten the nut securely and install the kick-down linkage and
return spring. The kick-down cable can now be attached to the ball socket. Ensure
that the wiring harness has some dielectric grease on it and connect it. Ensure not
to bend the pins when attaching the plug.
27. When just the valve body is being replaced, the transmission will need ~8-9 quarts of
ATF+3. When both the valve body and torque converter are being replaced, ~15-17
quarts are required.
IMPORTANT: After 8 quarts have been added, start the engine and shift through all
gears, and then check the transmission oil level with the shifter in neutral. Top up and
check as required. DO NOT OVERFILL!
28. After your test drive, check the oil levels again. Air locks are common in this
transmission.
29. Road test the vehicle to verify pressures and to check for the wide-open shift points
to ensure that they are correct.
These pressures will vary according to the position of the kick down cable adjustment
and the lock-up boost valve. Engine RPM DOES NOT affect line pressure.
CAUTION – PRESSURE SETTINGS THAT ARE TOO HIGH CAN RESULT IN SEVERE
SHIFTS, LIMP MODE, or 2ND OR 3RD GEAR STARTS.
BD Engine Brake, Inc.
Plant Address: Unit A10, 33733 King Rd, Abbotsford, BC, Canada V2S 7M9
U.S. Shipping Address: 88-446 Harrison St, Sumas, WA 98295 U.S. Mailing Address: P.O. Box 231, Sumas, WA 98295
Phone: 604-853-6096 Fax: 604-853-8749 Internet: www.bd-power.com
28 November 2006
ValveBody #1030418 / 1030419
8
Kick Down Cable Adjustment
The adjustment of the kick down cable is one of the most critical adjustments that affect
the operation of the transmission.
The BD Performance Valve Body is not stock, therefore the factory specifications for this
adjustment are used only as a guide.
Your drivability and performance demands will determine your shift points and pressure
adjustments.
Kick down cable adjustments are for Full Throttle shift points & passing gear only. Light
throttle shift points should be adjusted on the valve body throttle valve stop.
The kick down cable is located underneath the plastic cover as indicated above.
The plastic cover is held in place by 2 plastic Phillips head screws. Only light pressure is
required to remove them. Do not lose the screws or washers when you remove them.
Full throttle shifts between 2nd and 3rd should occur between 2800 - 3000 rpm (OEM) at
operating temperature.
BD Engine Brake, Inc.
Plant Address: Unit A10, 33733 King Rd, Abbotsford, BC, Canada V2S 7M9
U.S. Shipping Address: 88-446 Harrison St, Sumas, WA 98295 U.S. Mailing Address: P.O. Box 231, Sumas, WA 98295
Phone: 604-853-6096 Fax: 604-853-8749 Internet: www.bd-power.com
28 November 2006
ValveBody #1030418 / 1030419
9
Locate the kick down cable and remove it
from the throttle linkage and support
bracket.
IMPORTANT – Before any adjustments
are made, MARK THE CABLE at its
original setting.
Remove the white colored locking clip.
**CAUTION**
DO
NOT
USE
A
SCREWDRIVER TO PERFORM THIS
FUNCTION. IF THE CLIP BREAKS, THE
CABLE WILL HAVE TO BE REPLACED.
Adjust the cable forward (towards the
radiator), to make the transmission shift
earlier.
Adjust the cable back to the rear (towards
the firewall), to make the transmission shift
later.
1/8” movement = ~75RPM
Re-install the white locking clip and re-install the cable through the support bracket and
then onto the throttle lever. Install the plastic cover when complete.
BD Engine Brake, Inc.
Plant Address: Unit A10, 33733 King Rd, Abbotsford, BC, Canada V2S 7M9
U.S. Shipping Address: 88-446 Harrison St, Sumas, WA 98295 U.S. Mailing Address: P.O. Box 231, Sumas, WA 98295
Phone: 604-853-6096 Fax: 604-853-8749 Internet: www.bd-power.com
28 November 2006
ValveBody #1030418 / 1030419
10
Pressure Adjustments
Valve Body pressure adjustments and throttle valve cable adjustments affect each other.
For example, if you raise pressure, the transmission may shift sooner and vice versa).
TAKE YOUR TIME WHEN MAKING THESE ADJUSTMENTS TO ENSURE THAT THE
TRANSMISSION PERFORMS TO YOUR PREFERRED DRIVING STYLE.
If the pressures are not according to specifications, please call our Transmission
Technical department for assistance. The valve body is designed and tested with a
specified pump volume.
Different pressures are due to non-standard pump
characteristics, which is why you must check the pressures before performing this
modification.
1 full turn = ~75 rpm
HARD SHIFTING / 2 or 3 GEAR STARTS DECREASE PRESSURE
LIGHT SHIFTING / STACK SHIFTS INCREASE PRESSURE
nd
rd
BD Engine Brake, Inc.
Plant Address: Unit A10, 33733 King Rd, Abbotsford, BC, Canada V2S 7M9
U.S. Shipping Address: 88-446 Harrison St, Sumas, WA 98295 U.S. Mailing Address: P.O. Box 231, Sumas, WA 98295
Phone: 604-853-6096 Fax: 604-853-8749 Internet: www.bd-power.com
28 November 2006
ValveBody #1030418 / 1030419
11
Governor Pressure Out Of Limit Trouble Code
If you receive a “GOV PRESSURE OUT OF LIMIT” causing LIMP MODE (stuck in 3rd
gear) trouble code, then you must check the voltage at Pin # 31 at the PCM.
PCM Connectors: Under hood on fire
wall. Remove air box for easy access.
Remove middle cover and locate
Orange wire at pin #31.
Isolate wire and install resistor.
Resistor can be installed either way.
Solder and use shrink tubing.
IMPORTANT - Dodge requires that Pin 31 on the PCM connector has a signal of ~+5.0
V. Because some vehicles produced have a signal voltage higher than this (5.1 – 5.3V),
this modification allows the voltage to remain below @ 5.0 V as required to ensure a
trouble code of “Gov Pressure Out Of Limit” causing limp mode (stuck in 3rd gear).
If the voltage at Pin 31 is HIGHER than +5.1V, then install a 100 Ohm, ¼ watt resistor to
bring the voltage below +5 V.
BD Engine Brake, Inc.
Plant Address: Unit A10, 33733 King Rd, Abbotsford, BC, Canada V2S 7M9
U.S. Shipping Address: 88-446 Harrison St, Sumas, WA 98295 U.S. Mailing Address: P.O. Box 231, Sumas, WA 98295
Phone: 604-853-6096 Fax: 604-853-8749 Internet: www.bd-power.com
28 November 2006
ValveBody #1030418 / 1030419
12
2004 Vehicles
Due to the single ECM in 2004 vehicles, the location of the 5 Volt supply wire has
changed. It is now located at Pin 23 which is a Yellow wire with a Pink tracer.
Questions?
If you require assistance with this kit, please call our Transmission Technical Support
Line at (800) 887-5030, Monday to Friday from 8:00-4:00pm Pacific Standard Time
(PST). As an alternative, you can post a support question on our technical forum, located
at http://www.bd-power.com/forum/ .
BD Engine Brake, Inc.
Plant Address: Unit A10, 33733 King Rd, Abbotsford, BC, Canada V2S 7M9
U.S. Shipping Address: 88-446 Harrison St, Sumas, WA 98295 U.S. Mailing Address: P.O. Box 231, Sumas, WA 98295
Phone: 604-853-6096 Fax: 604-853-8749 Internet: www.bd-power.com
28 November 2006
ValveBody #1030418 / 1030419
13
BD ENGINE BRAKE, INC.
WARRANTY STATEMENT
BD Engine Brake, Inc. (BD) warrants to the original purchaser that any products purchased shall
be free from defective parts and workmanship. A defect is defined as a condition that would render the
product inoperable. BD limits the liability to the repair or replacement, at BD’s option, of any warrantable
product returned with a complete service history and proof of purchase. A valid proof of purchase is a
dated bill of sale. Repaired or replaced products shall be returned to the customer freight collect.
Accepted warranty units, which have been replaced, become the sole property of BD.
A Return Material Authorization (RMA) number obtained in advance from a BD customer service
representative must accompany product returned, with shipping prepaid by the purchaser, for warranty
determination. BD will be the final authority on all warranty decisions.
Labor costs incurred by the removal and replacement of a BD product, while performing warranty
work, will be covered for 6 months at authorized service centers. Until the product has been approved
at the original installing dealer or at one of our distributors, the consumer shall be responsible for these
costs.
NOT COVERED UNDER THIS WARRANTY
This warranty shall not apply to any product that has been improperly stored or installed; or to
misapplication, improper operation conditions, accidents, or neglect, or which has been improperly
repaired or altered or otherwise mistreated by the owner or his agent. This product warranty shall
terminate at the end of 12 months or 24,000 miles of service, which ever comes first, with the original
purchaser.
The nature of this product is PERFORMANCE and is designed to perform above OEM
specifications. This product was designed with this in mind and should NOT be used in RACING and/or
HIGH HORSEPOWER applications and will only be considered for warranty on vehicles with a
maximum of 300 REAR WHEEL HORSEPOWER. Using this product on vehicles with a higher rating
will cause premature failure and therefore BD will not consider such claims.
Except as set forth in our product outline, BD disclaims any implied warranties of merchantability
and fitness for a particular purpose. BD also disclaims any liability for incidental or consequential
damages including but not limited to, repair labor, rental vehicles, hotel cost or any other inconvenience
costs. This warranty is in lieu of all other warranties or guaranties, either expressed or implied, and shall
not extend to any consumer or to any person other than the original purchaser residing within the
boundaries of the continental U.S. or Canada.
BD Engine Brake, Inc.
Plant Address: Unit A10, 33733 King Rd, Abbotsford, BC, Canada V2S 7M9
U.S. Shipping Address: 88-446 Harrison St, Sumas, WA 98295 U.S. Mailing Address: P.O. Box 231, Sumas, WA 98295
Phone: 604-853-6096 Fax: 604-853-8749 Internet: www.bd-power.com