Installing the BD Dodge Valve Body

Installing the BD Dodge Valve Body
30 March 2007
Valve Body #1030415 / 1030416 / 1030417
1
BD VALVE BODY
For 1994-1998 Dodge 5.9L 12/24V Cummins Trucks
-- Installation Instructions --
1030415
1030416
1030417
1994-1995 Dodge 12V
47RH
1996-1998 Dodge 12V
47RE
1998½-1999 Dodge 24V
47RE
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
30 March 2007
Valve Body #1030415 / 1030416 / 1030417
2
Tools Required
•
•
•
•
•
•
•
Inch Pound Torque Wrench
3/8” or ½” Dr Socket sets including 11mm & 13mm socket
#25 Torx Bit
Combination Wrench Set including 7/16” & ¾”
3/16” Allen wrench
High Quality Pressure Gauge (0 - 160 psi)
Voltmeter
Additional Parts Required (Not Included)
• Type PLUS 3 ATF (recommended)
• 2 Bottles of Red Lubeguard (recommended)
All Diesel Rams must 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 convertor and transmission wearing
characteristics (soft or severe shifting, high transmission temperature).
12 Valve
2400-2500 rpm (wide open throttle)
24 Valve
2800-3000 rpm (wide open throttle)
Ensure shift points are correct before
recording pressures (transmission at
operating temperature).
47RE Transmissions
Transmission Line Pressure
OEM Pressure
BD Pressure
Transmission in DRIVE w/Engine at
idle
55-65psi
70-85psi
Transmission in DRIVE w/Convertor
Locked up @ 1800 - 1900 rpm
64-72psi
85-90psi
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
30 March 2007
Valve Body #1030415 / 1030416 / 1030417
3
Transmission Shift Points
Transmission Shift Point (RPM)
Before
After
2nd – 3rd Shift point (Normal Driving)
2nd – 3rd Shift point (Wide Open Throttle)
Installation Notes
IMPORTANT - IF PRESSURES AND/OR SHIFT POINTS ARE NOT TO SPECS THE
TRANSMISSION MUST BE REPAIRED OR SERVICED BEFORE MODIFICATIONS.
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 later testing.
VERY IMPORTANT - Road test with 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.
Pressures will only be indicated with transmission in Drive position.
Secure the vehicle with wheel chocks and place the transmission in Neutral.
Ensure the valve body has not been damaged in shipping and it is the proper part
number for your vehicle.
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
30 March 2007
Valve Body #1030415 / 1030416 / 1030417
4
Installation
1.
Starting at the transmission, remove
the kick down lever and spring as well
as the hitch/clevis pin from the shifter
rod. DO NOT lose the wave washer.
2.
Rotate the shift lever to the rear of the
vehicle to place the transmission in the
PARK position.
3.
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 the
shift lever.
4.
Disconnect the wiring connectors from
the Neutral Safety switch and valve
body, and then remove the Neutral
Safety switch.
5.
Install a large drain pan under the transmission, remove the oil pan, drain the
transmission oil, and then remove the filter.
6.
Carefully remove the E-clip from the park rod, leaving the park rod in the
transmission.
7.
Remove the 10 valve body bolts, remembering the location of the different bolts.
The valve body mounting bolts are different lengths and MUST be
reinstalled in the proper location.
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
30 March 2007
Valve Body #1030415 / 1030416 / 1030417
8.
When lowering the valve body, gently
work it around so that the park rod
lever is left in the transmission, and
ensure the electrical plug is not
damaged in the removal process.
9.
CAUTION - As you lower the valve
body, watch for the accumulator piston
and spring falling out.
5
10. This is the time to change the 2nd gear band strut to the heavy duty one we supply.
Loosen the band adjusting screw lock nut with a 3/4” wrench, and then unscrew the
adjuster until the stock strut can be removed.
Stock band strut in place
New BD band strut in place
11. Install the new BD strut with the tapered side down, towards the pan, and center into
the guides. Torque the band adjustment to 72 lbs-in., then back out 1 7/8” turns and
tighten the 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.
12. IMPORTANT - Before installing the BD valve body, lubricate the manual-shifting
shaft and the O-ring on the electrical connector that fits into the transmission case.
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
30 March 2007
Valve Body #1030415 / 1030416 / 1030417
6
Rotate the shift lever all the way forward to place the valve body in the 1st / Low gear
position for later attaching of the park rod and E-clip.
Place the accumulator piston and spring in
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.
13. 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.
14. Install the E-clip on the park rod using
the flat, slotted end of the Canadian
micro-hockey stick tool.
“Hockey Stick” Tool
15. Install the valve body mounting bolts, ensuring the different length bolts are installed
in the proper positions, and torque evenly to 10 lbs-ft.
16. 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 to Park. Leave in the neutral position and tighten the retaining bolt.
17. Install the neutral start switch and tighten.
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
30 March 2007
Valve Body #1030415 / 1030416 / 1030417
7
18. Install the new filter on the valve body using 3 screws, instead of the 2 that the OEM
filter was attached with (stock on 97-00 trucks).
19. We suggest 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.
20. Install the shift linkage to the manual lever on the transmission using the wave
washer and hitch pin. Tighten nut securely and install kick-down linkage and return
spring. The kick-down cable can now be attached to the ball socket. Ensure the
wiring harness has some dielectric grease on it and connect. Ensure not to bend the
pins when attaching the plug.
21. 1996-1998 trucks with 12-valve engines have a one way check valve in the hose
located under the heat exchanger under the turbo. This check valve was used with
the stock valve body to prevent the oil from draining back from the cooler line. This
can stick, restricting oil flow. It is suggested that you replace it with a free flowing
line such as BD part # 1300007, seen below.
BD Check Valve Hose
Stock Check Valve Hose
22. When removing the oil flow lines on
newer vehicles, you will note that some
of these have quick-disconnect, Teflon
type fittings.
These fittings are prone to premature
failure and should be replaced to prevent
them from blowing off. This would cause all
fluid to be lost and subsequent damage to
the transmission and torque converter.
P/N 1400127 Heat Exchange Fitting (X2)
P/N 1400099 Transmission Line Fitting (X2)
New Fitting
Teflon Fitting
23. When just the valve body is replaced, the transmission will need approximately 8-9
quarts of ATF+3. When both the valve body and torque converter are being replaced,
approximately 15-17 quarts are required.
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
30 March 2007
Valve Body #1030415 / 1030416 / 1030417
8
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!
24. After a test drive, check the oil levels again. Air locks are common in this
transmission.
25. Road test the vehicle and check for the wide-open shift points to ensure they are
correct and to verify pressures. 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.
**Note** Different specifications (shift points/pressure) for the ISB engine.
**CAUTION** – PRESSURE SETTINGS TOO HIGH CAN RESULT IN A SEVERE
SHIFT, LIMP MODE, or 2ND OR 3RD GEAR STARTS.
WARNING
WHEN YOUR TRANSMISSION IS SERVICED AT A DEALER OR SERVICE CENTRE
IT IS IMPERATIVE THAT THE BD FILTER BE REPLACED WITH THE SAME TYPE.
THE PROPER FILTER IS CHRYSLER OEM PART # 3515996 WHICH WILL ENSURE
THE MODIFIED VALVE BODY DOES NOT LEAK PAST THE FILTER SEAL.
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
30 March 2007
Valve Body #1030415 / 1030416 / 1030417
9
Kick Down Cable Adjustment
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 a performance product and 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.
12 VALVE ADJUSTMENTS
On trucks equipped with the 12-valve 5.9 6BTA Cummins engine (1994-98 12 valve), full
throttle shifts between 2nd-3rd gear should occur between 2400–2500RPM (OEM) with the
transmission at operating temperature.
Locate the kick down cable and MARK THE CABLE at the original setting before any
adjustments are made.
NOTE: Disconnecting the cable from the support bracket and the throttle lever is a
difficult task - it may be easier to adjust it without removing the cable.
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
30 March 2007
Valve Body #1030415 / 1030416 / 1030417
Press the lock tab (this will take
considerable force) to release the
locking mechanism.
Adjusting the cable forward,
towards the radiator, will make
transmission shift sooner.
Adjusting the cable rearward,
towards the firewall, will make
transmission shift 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
10
30 March 2007
Valve Body #1030415 / 1030416 / 1030417
11
24 VALVE ADJUSTMENTS
On trucks equipped with Cummins ISB engines, full throttle shift between 2nd and 3rd
should occur between 2800 – 3000RPM (OEM) with the transmission at operating
temperature.
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.
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.
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
30 March 2007
Valve Body #1030415 / 1030416 / 1030417
12
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
Install white locking clip and then re-install the cable thru the support bracket and then on
to the throttle lever.
Install plastic cover when job is 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
30 March 2007
Valve Body #1030415 / 1030416 / 1030417
13
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
30 March 2007
Valve Body #1030415 / 1030416 / 1030417
14
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
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