97232_Dodge Exhaust Brake System-v3.indd

97232_Dodge Exhaust Brake System-v3.indd
Owner’sManual
with Installation Instructions
Banks Brake®
Exhaust Brake System
Late 2004-2007 Dodge Cummins ISB Pickup
Trucks with Manual Transmissions
THIS MANUAL IS FOR USE WITH EXHAUST BRAKE SYSTEMS 55227 & 55228
Gale Banks Engineering
546 Duggan Avenue • Azusa, CA 91702
(626) 969-9600 • Fax (626) 334-1743
Product Information & Sales: (888) 635-4565
bankspower.com
©2012 Gale Banks Engineering
03/20/12 PN 97232 v.3.0
Products available from Banks Power
for the ‘03-07 Dodge 5.9L
BigHead®
Wastegate
Monster
Exhaust
Banks iQ
Banks Bullet™
Banks Billet™
Torque Converter
DynaFact ®
Instrumentation
®
Monster-Ram
Advanced
Diesel Tuners
Banks Brake®
Banks Ram-Air ®
Intake
Techni-Cooler®
System
Super-Scoop®
Banks iQ System
(P/N 61148-61149)
• 5” touchscreen interface that can
control the Banks Diesel Tuner on the fly.
• Interchangable gauge display, read
and clear codes, monitor engine
diagnostics, log data, time your vehicles
runs and much more.
Banks Monster® Exhaust System
Single (P/N 48640-48643, 48700,
48701, 48708)
Duals (P/N 48702-48707, 48709
Sport (P/N 48777-48780)
• Increases exhaust flow, cuts
backpressure, lowers exhaust gas
temperatures (EGTs) and increases
power.
Banks Ram-Air Intake System
(P/N 42145)
• Increases your airflow over stock.
• Adds power, improves fuel economy,
lowers EGTs and reduces smoke.
Banks Ram-Air Intake Super-Scoop
(P/N 42190-42191)
• Adds cooler denser air to the Ram-Air
Intake housing, further increasing fuel
economy, reducing smoke and lowers
EGTs.
2
97232 v.3.0
Banks Monster-Ram
(P/N 42765-42766)
• Increased flow from intercooler
• Raises boost without increasing
backpressure at the turbine
Big Hoss Intake Manifold System
(P/N 42747)
• Increases flow and provides more
uniform air distribution to the engine for
more available power at a given boost
level.
Banks Techni-Cooler® System
(P/N 25980-25981)
• Provides increased air flow to the
engine by increasing air density for
more increased power, lower EGTs and
improved fuel economy.
Banks SmartLock
(P/N 55270)
• Reduces wear on transmission
• Locks Torque Converter and raises
trans-line pressure
• Works with Banks Exhaust Brake
Boost and Pyro Gauges
(P/N 64507)
• Keep your engine safe by monitoring
vital engine parameters.
Banks Billet Torque Converter
(P/N 72515)
•Higher torque capacity over stock
•Lockup clutch is slip-resistant so
transmission fluids stay cooler and
transmission life is prolonged.
Banks Bullet
(P/N 66522-66523)
•Adds power safely to your vehicle
•Displays critical engine functions
•Engine safeguards
•Change power levels on-the-fly
Banks Diesel Tuner
EconoMind w/switch (P/N 63725,
63793, 63795, 64507)
EconoMind w/iQ (P/N 63807, 63808,
63817, 63818)
Six-Gun w/switch (P/N 61022, 63797)
Six-Gun w/iQ (P/N 63809, 63819)
•Adds power safely to your vehicle
•Engine and transmission safeguards
•Change power levels on-the-fly
Thermocouple
•Add a temperature limiting function to
your Diesel Tuner.
Banks Speed-Loader
(P/N 62981)
•Furthers the power output of the
Banks Six-Gun and provides EGT limiting
safety.
Banks BigHead® Actuator
(P/N 24331)
•Achieves a higher peak boost over
stock and gives you precise boost
control that gives you crisp acceleration
and more mid-range pulling power.
Banks Stinger Systems
(P/N 49692-49699, 49708-49711,
49716-49721)
Contains:
•Ram-Air Intake system
•Monster Exhaust (single or dual)
•EconoMind Tuner w/ Banks iQ
•Big Head Wastegate Actuator
Banks PowerPack Systems
(P/N 49700-49707, 49712-49715,
49722-49727)
Contains:
•Ram-Air Intake system
•Monster Exhaust (single or dual)
•EconoMind Tuner w/ Banks iQ
•Big Head Wastegate Actuator
•Monster-Ram
•Techni-Cooler System
Banks Six-Gun Bundle
(P/N 49728-49735, 49744-49747,
49752-49757)
Contains:
•Ram-Air Intake system
•Monster Exhaust (single or dual)
•Six-Gun Tuner w/ Banks iQ
•Big Head Wastegate Actuator
Banks Big Hoss Bundle
(P/N 49736-49743, 49748-49751,
49758-49763)
Contains:
•Ram-Air Intake system
•Monster Exhaust (single or dual)
•Six-Gun Tuner w/ Banks iQ
•Big Head Wastegate Actuator
•Monster-Ram
•Techni-Cooler System
For More Information please call (888) 635-4565
or Visit us online @ www.bankspower.com
97232 v.3.0
3
Limitation of Warranty
Gale Banks Engineering Inc. (hereafter
“SELLER”), gives Limited Warranty as
to description, quality, merchantability,
fitness for any particular purpose,
productiveness, or any other matter of
SELLER’s product sold herewith. The
SELLER shall be in no way responsible
for the product’s open use and service
and the BUYER hereby waives all rights
except those expressly written herein.
This Warranty shall not be extended
or varied except by written instrument
signed by SELLER and BUYER.
WARNING! The Vacuum Pump
must never be run open to the
atmosphere, as this will damage
the Pump diaphragm. The Pump
must always be connected to the
Vacuum Solenoid or it’s vacuum
nipple must be plugged. The
warranty on the Pump will be
voided if the Pump is allowed to
run open to the atmosphere.
Please see enclosed warranty
information card, or go to www.bankspower.com/warranty,
for warranty information regarding your
product. Parts or devises outside the
products kit are not covered under Gale
Banks Engineering warranty. All products
that are in question of Warranty must be
returned shipping prepaid to the SELLER
and must be accompanied by a dated
proof of purchase receipt. All Warranty
claims are subject to approval by Gale
Banks Engineering Inc.
The buyer may promptly return
this product, in a new and unused
condition, with a dated proof-ofpurchase, to the place-of-purchase
within thirty (30) days from dateof-purchase for a full refund, less
shipping and/or restocking fee.
Under no circumstance shall the SELLER
be liable for any labor charged or travel
time incurred in diagnosis for defects,
removal, or reinstallation of this product,
or any other contingent expense.
Under no circumstances will the SELLER
be liable for any damage or expenses
incurred by reason of the use or sale of
any such equipment.
4
97232 v.3.0
In the event that the buyer does
not agree with this agreement:
The installation of this product
indicates that the buyer has read
and understands this agreement
and accepts its terms and
conditions.
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
and operation of the Banks
Exhaust Brake, please call our
Technical Service Hotline at
(888) 839-2700 between 7:00 am
and 5:00 PM (PST). IF YOU HAVE
ANY QUESTIONS RELATING TO
SHIPPING OR BILLING, PLEASE
CONTACT OUR CUSTOMER
SERVICE DEPARTMENT AT (888)
839-5600.
Thank you.
1. For ease of installation of your
Banks Brake Exhaust Brake System,
familiarize yourself with the procedure
by reading the entire manual before
starting work.
2. Inspect all components supplied
for any foreign material that may have
entered during shipping and handling.
3. The installation should be
performed at a time when the vehicle
has been allowed to completely cool.
This installation requires the installer
to work near surfaces that may remain
hot after the vehicle has been run.
Failure to allow the vehicle to cool
may result in personal injury.
4. Throughout this manual, the
left side of the vehicle refers to the
driver’s side, and the right side refers
to the passenger’s side of the vehicle.
5. Throughout this manual, major
components of the Banks products are
capitalized to make it easier to identify
them.
6. Pay particular attention to the
routing of wires. Keep them away from
exhaust heat, moving parts and sharp
edges that may cause 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.
7. During installation, keep the
work area clean. If foreign debris
is transferred to any Banks system
component, clean it thoroughly before
installing.
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.
WARNING! The Vacuum Pump
must never be run open to the
atmosphere, as this will damage
the Pump diaphragm. The Pump
must always be connected to the
Vacuum Solenoid or it’s vacuum
nipple must be plugged. The
warranty on the Pump will be
voided if the Pump is allowed to
run open to the atmosphere.
97232 v.2.0
5
Table of Contents
Tools Required:
• 1⁄ 2”
and 3⁄ 4” drive ratchets with inch
and metric sockets and 1⁄ 2” and
3⁄ 8” drive extension
• 1⁄ 2”
drive breaker bar or belt tool
• Inch and metric combination or
open-end wrenches
• Standard screwdriver
• Clean shop towels or rags
• Pliers
• Needle nose pliers
• Hex wrench
• Utility knife
• Electric drill
• 1⁄ 2”
Uni-bit or drill bit
• Inch-pound and foot-pound torque
ratchets
Section 1 . . . . . . . . . . . . . . . . . . . . .5
Bill of Materials and General Assembly
Section 2 . . . . . . . . . . . . . . . . . . . . .8
Banks Exhaust Brake Installation
Section 3 . . . . . . . . . . . . . . . . . . . .12
Vacuum Solenoid and Relay Installation
Section 4 . . . . . . . . . . . . . . . . . . . .14
Vacuum Pump Installation
Section 5 . . . . . . . . . . . . . . . . . . . .16
Banks Brake Wiring Harness Installation
Section 6 . . . . . . . . . . . . . . . . . . . .23
Brake Enable Switch Installation
Section 7 . . . . . . . . . . . . . . . . . . . .29
Functional Testing
Section 8 . . . . . . . . . . . . . . . . . . . .30
Safety and Operation/ Driving Tips
Section 9 . . . . . . . . . . . . . . . . . . . .35
Troubleshooting
• Penetrating oil or light lubricant
spray
Note for 2006-07 trucks: Before
starting, it may be necessary to have
an extra bottle of coolant on hand
to top off the radiator when finished
installing the Banks Exhaust Brake
System. Follow the manufacture’s air
bleeding procedures.
Replacement belt numbers:
Banks
65120
Gatorback
4081295
Napa
25081298
Dayco
5081300
Mopar
53041270AA
Cummins
3947077
Note: If you cannot find the above part
numbers, ask for a belt that fits 2004- 07
Ford E350-450 Econoline van with 6.0L
Diesel engine and single alternator
6
97232 v.3.0
Bill of Materials
Description
Part #
Kit 55227
Kit 55228
Assembly, Brake Housing
55045
1
1
Vacuum Pump
55176
1
1
Bracket, Vacuum Pump
55177
1
1
Hex Bolt, Washer Head, Black,
M8 x 1.25 x 25mm
91809
3
3
Hex Bolt, Washer Head, Black,
M8 x 1.25 x 40mm
91815
4
4
Vacuum Solenoid
55138
1
1
Relay
55136
1
1
Switch, Banks Brake
62130
1
1
Washer, #10 External Tooth, Zinc
91832
1
1
Machine Nut, #10-32, Zinc
91833
1
1
Machine Screw, Pan Head, Phillips #1032 x 1⁄2”
91834
1
1
Washer, #10 SAE
91835
1
1
Hex Bolt, Zinc, M6 x 1.00 x 25mm
Washer, SAE, Flat, Zinc, 1⁄4”
91742
2
2
91102
2
2
Nut, Nylock, Hex, Zinc, M6 x 1.0
91771
2
2
Wiring Harness
55408
1
1
Heater Core Tube, 2006+, manual
25571
Hose, 7⁄32” 1.5 ft
Hose, 5⁄16” 5 ft
94128
1
1
94129
1
1
Belt, Serpentine, Vacuum Pump
65120
1
1
Urocal, Banks Power, Small
96009
2
2
Product Registration Card
96412
1
1
Owners Manual
97232
1
1
Warranty Statement
96503
1
1
Cable Ties, 8”
62010
25
25
1
97232 v.3.0
7
Section 1
General Assembly
Figure 1
Figure 2
8
97232 v.3.0
Figure 3
97232 v.3.0
9
Section 2
Banks Exhaust Brake Installation
1. As a precaution, disconnect the
Note: It may be necessary to loosen
or remove the exhaust support from
the transmission to provide extra
clearance.
2.
Push the exhaust pipe to the rear
of the vehicle slightly to allow the
elbow to be removed. Slide the elbow
towards the rear of the vehicle to
allow the alignment pins in the turbo
to come free.
ground of the battery (if there is more
than one battery, disconnect both
grounds).
Raise the front of the vehicle and
support it with properly weight rated
safety stands or a commercial hoist.
Follow the manufacturer’s safety
precautions. Take care to support the
vehicle to prevent it from slipping or
falling. Place the transmission in park;
set the parking brake and place blocks
behind the rear wheels.
3.
Remove the front passenger side
wheel and the wheel well splash
shield.
If equipped, detach the ABS wire that
is clipped on the passenger side splash
shield before completely removing the
shield to avoid damage to the wire.
4.
Remove the exhaust elbow that
is attached to the turbo outlet by
loosening the V-clamps and slide them
off the lip. Spray with penetrating
lubricant to ease removal (Figure 4).
Figure 4
10
97232 v.3.0
If the elbow doesn’t come lose, then it
may be necessary to break it lose from
the alignment pins. Wear appropriate
eye protection and firmly strike the
elbow with a hammer or light sledge
hammer.
Note: Retain the factory V-clamps for
use later. The alignment pins will have
to be removed or broken lose from the
turbo’s outlet flange. Make sure the
turbo’s outlet flange surface is flat so
that it doesn’t interfere with proper
exhaust sealing.
2006+ trucks, proceed to Step 5.
All other years, proceed to Step 8.
5. For 2006+ trucks, the heater core
tube that is above the exhaust pipe
will have to be replaced with the
Banks Heater Core Tube to provide
additional clearance for the Brake.
6. Drain the radiator fluid into a
suitable container to be re-used.
Loosen the hose clamps and remove
the heater hoses from the heater core
tube. Remove the two (2) nuts that
attach the coolant line to the engine.
See Figure 5 for the passenger side
nut and bolt.
7. Replace the factory heater core
tube with the Banks Heater Core Tube.
Install and tighten the nuts. Re-install
the heater hoses making sure that
they are properly inserted on the
pipe. Slide hose clamps back into
place. Refill the radiator and follow
manufacture’s air bleeding procedures.
8.
The transmission dip stick tube
needs to be adjusted to allow for
added clearance for the lower exhaust
brake V-clamp. Loosen or remove the
bolt(s) that hold it in place and adjust
as needed after the Banks Brake is in.
9. Slide the larger sized factory
V-clamp on the exhaust pipe.
10. Locate the supplied Banks
Exhaust Brake assembly and slide the
factory V-clamp over the inlet of the
brake. Orientate your brake as shown
in Figure 6.
Note: Do not worry if the Brake
actuator arm touches the fire wall
insulation. This will not effect the
action of the Brake. Make sure that
the Brake lever is fully seated against
it’s stop. See Figure 7.
Figure 5- Passenger’s side
97232 v.3.0
11
Figure 6
Figure 7
12
97232 v.3.0
11.
Slide the V-clamp that is on the
Brake assembly onto the turbo outlet.
Make sure that the flanges on the
Banks Brake and the turbo’s outlet
are centered in the V-clamp. Loosely
tighten the clamp.
12.
Clamp the Brake and exhaust
pipe together with the V-clamp that
was placed over the exhaust.
13. Tighten the V-clamps.
14. If the exhaust support was
removed, re-attach it to the
transmission.
15. Reinstall the wheel wells, tires
and lower the truck to the ground.
-END SECTION 2-
Note: If the exhaust support was
removed, a block of wood on a jack
or a friend may help in lining up the
exhaust pipe to the Banks Brake
easier.
97232 v.3.0
13
Section 3
Vacuum Solenoid and Relay Installation
1. Locate the rail along the top rear of
the engine compartment. Remove the
push-in retainer that is closest over
the exhaust brake with an upholstery
tool or screw driver.
2. Locate the supplied Banks
Vacuum Solenoid along with it’s 1⁄4”
flat washer, M6 x 1.0mm x 25mm
bolt, and M6 x 1.0 Nylock nut. Place
the Vacuum Solenoid over the hole
where the previously removed pushin retainer was removed. Install the
bolt though the Solenoid bolt hole and
the rail on the truck. Slide the 1⁄4” flat
washer onto the bolt, thread the 1⁄4”
Nylock nut onto the bolt, and tighten.
See Figure 8.
3. Using the supplied 7⁄32” hose for
the Exhaust Brake, slip one end onto
the Banks Exhaust Brake Actuator
nipple. See Figure 9. Make sure it is
secured properly. Run the tubing up
Figure 8
14
97232 v.3.0
to the Solenoid along the transmission
dipstick tubing to the right side nipple
of the Solenoid (Port 2). Cut the tubing
to length and slide fully onto Port 2 of
the Solenoid. Secure the hose away
from sharp, hot and/or moving parts
with a cable tie.
4. Insert the supplied 5⁄ 16” hose onto
the left side nipple of the Solenoid
(Port 1). Run the hose along the wiring
harness to the intake on the driver’s
side of the engine.
Note: Don’t secure the vacuum tubing
yet. It will be secured in a later step.
5. On the rail along the top rear of
the engine compartment, remove the
push-in retainer that is near the brake
fluid reservoir with an upholstery tool
or screw driver. Install the Relay in the
same manner as the Vacuum Solenoid
(Figure 10).
-END OF SECTION 3-
Figure 9
Figure 10
97232 v.3.0
15
Section 4
Vacuum Pump Installation
1. Use a 1⁄ 2” drive ratchet or breaker
bar to loosen the tensioner pulley to
create slack on the drive belt. Remove
the factory drive belt.
2. Locate the Banks Vacuum Pump
and attach it to the supplied Vacuum
Pump Bracket using the three
M8x1.25x25mm supplied bolts (Figure
11). Torque them to 18 ft-lbs (25 N*m).
3. With the four supplied
M8x1.25x40mm bolts, mount the
Vacuum Pump assembly to the rear of
the gear housing (Figure 12). Torque
the bolts to 18 ft-lbs (25 N*m).
Note: To provide additional clearance
when attaching the vacuum pump to
the gear housing, you may need to
remove the radiator support bracket.
This will allow the fan shroud some
freedom to move.
4.
Route the 5⁄ 16” hose from the
Vacuum Solenoid under the intake and
Figure 11
16
97232 v.3.0
to the Vacuum Pump nipple. Cut the
hose to length. Attach the hose to the
Pump. Secure the hose to the factory
wiring harness making sure it is away
from any heat source, sharp edges,
and/or moving parts. Make sure not to
crimp or pinch the hose closed.
5.
With the supplied Drive Belt, route
the Belt as shown in Figure 13. Use
the ½” drive ratchet or breaker bar on
the belt tensioner to allow the new
Belt to slide into place.
Note: If your vehicle does not have an
air conditioning pulley, you may have
to purchase a different accessory drive
belt. Its length will need to be 113.9”
(2,892mm).
6.
Make sure the Belt is properly
aligned around all the pulleys and
release the tensioner. See Vacuum
Pump warning on page 3.
-END SECTION 5-
Figure 12
Figure 13
97232 v.3.0
17
Section 5
Banks Brake Wiring Harness Installation
1. Locate the engine control module
(ECM) on the driver’s side of the
engine (Figure 14). Remove the ECM’s
50 pin connector with a 4mm hex
wrench.
2. The factory seals in locations #39
and #42 will have to be removed from
the 50 pin connector (Figure 15).
Figure 15 is viewed from the wire
side. Bend a paper clip so that part of
it is straight. On the side opposite the
wires, push the paper clip through pins
#39 and #42 to remove the factory
seals. You can use needle nose pliers
to help with the removal. See
Figure 16.
3. Locate the loose BLACK/RED and
BLUE terminal wires on the Banks
Wiring Harness. Insert the BLACK/
RED terminal wire into pin location
#39. Insert BLUE terminal wire into pin
location #42. Push in both terminals
until they snap into place and are
locked. Re-connect the ECM’s 50 pin
connector.
Note: Routing the wires between the
intake and the brake fluid reservoir,
down to the ECM’s connector will
provide the cleanest install.
4.
Remove the fuse box cover,
located in the front driver’s side of the
engine compartment. Locate mini-fuse
#50 for 2004-05 trucks (Figure 17)
or #28 for 2006-07 trucks (Figure 18)
and remove it.
5. Install the mini-blade fuse tap onto
the removed mini fuse as shown in
Figure 19. Re-install the mini fuse
with the attached blade tap into the
fuse box.
For 2004-05 trucks, install the fuse tap
in the #50 spot closest to the firewall
as seen in Figure 17.
For 2006-07 trucks, install the miniauto blade tap in the #28 spot closest
to the engine. This is the “hot” side of
the circuit.
Figure 14
1) Engine Control Module (ECM)
2) 60 pin connector
3) 50 pin connector
18
97232 v.3.0
Figure 15- Viewed from the wire side
Figure 16
97232 v.3.0
19
Figure 17
Figure 18
20
97232 v.3.0
Figure 19
7.
Attach the Ground wire (Black
wire with ring terminal) to an existing
bolt by removing the existing bolt and
sliding the ring terminal over the bolt.
Re-install the bolt. Use Figure 21 as
an example location on the driver’s
side fender.
Note: Make sure your ground
location is clean from dirt, grease and
corrosion or the Banks Brake may not
function properly.
8.
Route the Wiring Harness along the
A.C. hose. Secure it later with cable
ties after you have confirmed there
is enough Harness to reach all the
needed connectors.
6. Cut a small notch in the fuse box
cover and base, on the edge closest
to the engine (Figure 20), to avoid a
pinched or stressed wire. Locate the
Fuse Connector wire on the Banks
Wiring Harness and connect it to the
mini-blade fuse tap. Replace the fuse
cover and make sure not to pinch the
Fuse Connector wire.
Note: If a Banks Six-Gun or OttoMind
Diesel Tuner has been installed in the
vehicle, disconnect the Tuner’s RED
Power Terminal wire from the fuse tap
and connect the Banks Brake’s RED
Fuse Connector wire from the Banks
Exhaust Brake Harness. Connect
the Tuner’s Power Terminal wire to
the RED Tuner Power wire from the
Exhaust Brake Harness.
9. Locate the connector for the
Vacuum Solenoid on the Banks Wiring
Harness. Route the wire to Vacuum
Solenoid along the hose connected to
the Solenoid and plug in the connector
to the Solenoid as seen in Figure 22.
Secure the wire and vacuum hose to
the factory wiring harness with cable
ties.
10. Plug the Relay Connector, on the
Banks Wiring Harness, into the Relay.
11. Locate the rubber grommet
located on the driver’s side firewall.
Using a utility knife, cut a 1” slit
around the outer edge of the grommet
to allow the Brake Switch Connector
and Harness to slide through. See
Figure 23.
Note: It may be easier, or necessary,
to cut the grommet from inside the
truck (Figure 24).
CAUTION: Do not cut or damage
the factory wiring harness.
97232 v.3.0
21
Figure 20
Figure 21
22
97232 v.3.0
Figure 22
Figure 23
97232 v.3.0
23
Figure 24
12. From the engine compartment,
push the Brake Switch Connector
through the hole cut in the grommet.
13. From inside the vehicle, continue
to pull the Harness through the firewall
until 18” of the Wiring Harness comes
through.
24
97232 v.3.0
CAUTION: Pull gently to avoid
damage to the Wiring Harness
Connector or wires. Always pull
on the Wiring Harness housing
rather than the wires themselves.
-END SECTION 5-
Section 6
Brake Enable Switch Installation.
CAUTION: Do not use force
when working on plastic parts.
Permanent damage to the part
might result.
Note: Before drilling, confirm that
there is adequate room for the Brake
Enable Switch and wires behind the
dash. Make sure wires or obstructions
are cleared from the drilling area.
From where the Brake Enable Switch
will be located, make sure there is
enough wire on the Banks Wiring
Harness to reach the Switch.
These are just suggested locations. It
is possible to locate the Brake Enable
Switch where it is more comfortable.
Please confirm space behind dash
before drilling.
2004-2005 Brake Switch install
1. The Banks Brake Enable Switch can
be installed in one of two places. #1,
on the drivers side of the instrument
panel (IP) next to the steering column
(Figure 25) or #2, on the knee panel
above the brake release (Figure 26).
2. Location #1: Remove the
headlamp switch bezel on the driver’s
side by gently pulling on it. Disconnect
the electrical connector once the bezel
is removed.
3. To remove the center bezel,
open the ashtray and cup holder and
remove the retaining screw. Gently
pull on the center bezel to disengage
all the clips that attach the bezel
to the dash. Disconnect the four
(4) electrical connections after the
bezel is removed. Keep the screw for
reinstallation.
Figure 25 Location #1
97232 v.3.0
25
Figure 26 Location #2
4. Remove the cluster bezel by first
removing the two (2) screws at the
top. Gently pull on it and disengage
all the clips that attach the bezel
to the dash. Retain the screws for
reinstallation.
5. Cut out the supplied template
(Figure 32) and align the template
onto the front of the cluster bezel by
placing its left edge against the cluster
rib, and it’s bottom edge against the
cluster bottom edge. Use masking
tape to securely hold down the
template.
NOTE: Do not tape over the markings
on the template.
It may be necessary to trim some of
the cluster’s ribs for the Switch to fit.
Skip to Step 12.
6. Location #2: Remove the dash
side panel (Figure 27). Remove the 2
screws inside.
7. Remove the 2 screws at the
bottom of the center knee panel. Pull
at the top to disengage the clips that
hold the knee panel.
8. Pull at top of the left brake panel
to disengage it’s clips. If applicable,
disconnect any switch wires. Remove
the panel from the truck.
9. Cut out the supplied template
(Figure 33) and align the template
onto the rear of the brake panel
by placing it’s upper edge against
the upper edge of the panel. Refer
to Figure 28. Use masking tape to
securely hold down the template.
NOTE: Do not tape over the markings
on the template.
Skip to Step 12.
26
97232 v.3.0
Figure 27
Figure 28
97232 v.3.0
27
2006-2007 Switch install
10. Remove the lower dash knee
panel from the vehicle by removing the
two (2) screws at the bottom corners
of the panel (retain for re-installation).
There are also two (2) retaining clips
located at the top corners of the
panel, which hold the panel in place.
These clips can be released by gently
pulling on the corners of the panel.
Use caution to avoid damaging the
panel during removal.
Note: If your vehicle is equipped with
power adjustable pedals, remove the
power adjustable pedal switch wiring
connector from the rear of the panel
and move the panel aside.
On vehicles with a center console,
it may be necessary to remove the
console to ease removal of the lower
dash panel.
Figure 29
28
97232 v.3.0
11.
Cut out one of the supplied
templates (Figures 34, 35) and align
the template above the brake release
lever (Figure 29). If applicable, align
the template next to the power
adjustable pedal switch (Figure 30).
Place the template’s bottom edge
against the top edge of the brake
release trim. Use masking tape to
securely hold down the template.
Note: Do not tape over the markings
on the template.
12. Before drilling, double check
to make sure there is enough room
behind where the Banks Brake Enable
Switch will be located. It may be
necessary to make minor adjustments
to the switch’s location, as needed.
Choose one of the hole locations that
you would like to drill. Using a ½” Unibit, center the bit onto the ½” drill
location on the template and slowly
Figure 30
drill through the panel. Remove and
discard the template and any plastic
shavings.
Note: It is important that the hole
is drilled as close as possible to the
recommended location. The switch
may not clear the instrument panel
structure if the hole is shifted to
another location.
A pilot hole may be drilled first if a Unibit is unavailable. Use a drill bit smaller
than 1/2”.
13. Align the Banks Brake Enable
Switch label over the previously drilled
hole. Make sure the entire mounting
surface is clean and free of dirt and
oil before mounting the label. Clean
and dry as required using a cloth
dampened with rubbing alcohol or
similar cleaning solution.
CAUTION: Do not get any fluid
directly onto/into any electrical
equipment or equipment damage
may result.
14. Mount the Banks Brake Enable
Switch label onto the panel by peeling
off the protective backing from the
adhesive tape on the back of the
switch label. Hold the label against the
panel for approximately 20 seconds
while applying pressure to allow the
adhesive to properly adhere to the
surface.
15. Attach the Brake Enable Switch
wires to the Switch (BLACK to 1,
BLACK-RED to 2, RED to 3) as shown in
Figure 31.
16. Remove the chrome bezel nut
from the Switch shaft. Insert the
Switch shaft into the hole that was
drilled in the dash panel. Re-install the
chrome bezel nut.
17. Reconnect any electrical
connectors and re-install the
instrument panel(s).
18. Plug the Switch’s Connector into
the Banks Brake Wiring Harness Switch
Connector.
97232 v.3.0
29
Figure 31-Brake Enable Switch
19. Route all wiring away from any
pedals or other moving components.
Using the supplied cable ties, secure
the wiring under the dash. Secure all
wiring under the hood away from heat
sources, moving parts, or sharp edges.
20. Re-install the battery ground
cable(s).
-END SECTION 6-
30
97232 v.3.0
Section 7
Functional Testing
The Banks Brake has been designed for
your truck. It features:
• Quicker engine warm-ups.
• Compatible with cruise control.
• Compatible with Banks Diesel Tuners.
Note: The following testing should be
performed only after the vehicle has
been allowed to COMPLETELY COOL.
This test verifies the performance
of the warm-up feature of the Brake
System and must be performed with a
cold vehicle.
1. Verify that the Banks Brake Enable
Switch is in the “ON” position. The
Switch will light up.
2. Ensure that the accelerator pedal is
NOT depressed.
3. Start the engine and let it idle.
The Brake valve will close and can
be verified by the increased noise or
muffled sound of a restricted exhaust
pipe or by observing the Brake
actuator lever closing.
4. Slowly press the accelerator pedal.
The Brake valve will open. Release the
accelerator pedal and the Brake valve
will close.
Note: The engine speed (RPM) should
not exceed 1200 RPM prior to Brake
disengagement.
5. Allow the vehicle to reach normal
operating temperature. The Brake will
remain active until the vehicle reaches
approximately 175°F (79°C) engine
coolant temperature. Once the vehicle
warms up, the Brake will turn off.
6.
Obtain a vehicle speed of
approximately 40 MPH (64 KPH) in an
area where speeds of this nature are
safe and traffic is light. Confirm that
the Banks Brake Enable Switch is in
the “ON” position. The Switch will be
lit up. Release the throttle. The brake
should activate and the vehicle will
begin to slow. Bring the vehicle to a
safe stop (using the vehicle’s hydraulic
brakes). Turn the Banks Brake Enable
Switch to the “OFF” position.
Once the vehicle has passed all of
the tests outlined in Steps 1-6, the
installation of the Banks Brake system
is complete and ready for years of
reliable service.
-END SECTION 7-
97232 v.3.0
31
Section 8
Safety and Operation/ Driving Tips
CAUTION: Your Banks Brake is
NOT a substitute for the hydraulic
brakes on your truck. 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 this Exhaust
Brake is first and foremost a
safety device and it is most
efficient when used to prevent,
rather than correct a runaway
vehicle condition.
The use of a Banks Brake does not
increase the load capacity of your
vehicle. Gross Combined Weight
Rating specifications should always
be adhered to. The Banks Brake will
allow you to slow your vehicle more
effectively within your vehicle’s weight
specifications.
Use your Banks Brake to assist in
slowing your vehicle while traveling
down grades. To activate the Brake,
flip 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. The
32
97232 v.3.0
Brake will also work with your cruise
control. When activated, the Brake will
be on when coasting and off when
accelerating.
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 for the Brake valve to fully open
and eliminates the possibility of
excess exhaust back pressure being
introduced into the engine.
The Banks Brake features a user
selectable warm up mode. When
activated and the engine is cold
(below 175°F, 79°C), the Exhaust
Brake will activate to reduce the
amount of engine warm-up time
required. There may be an increase
in engine noise when the Brake is
closed. Once the vehicle reaches
operating temperature, the Brake will
open. The Brake will also open when
the accelerator pedal is depressed
at temperatures below 175°F (79°C).
This prevents soot build-up and keeps
the shaft assembly from sticking. It
eliminates the need for any additional
maintenance.
To activate the warm-up mode, put
the Enable Switch to the ON position.
-END SECTION 8-
2004.5-2005
Figure 32
Figure 33
97232 v.2.0
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34
97232 v.3.0
2006-2007
Figure 34
Figure 35
97232 v.3.0
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36
97232 v.3.0
Section 9
Troubleshooting
If the Banks Brake does not pass
the FUNCTIONAL TESTING or ceases
to function properly, re-check all
the connections per the installation
instructions. Make sure that electrical
connections are tight and secure and
that the vacuum hoses are not kinked or
pinched.
If the Brake Enable Switch does not light
up within a few seconds, the following
diagnostic procedures can be carried out
to identify and correct the problem:
1. With key on and the engine off,
turn the Brake Enable Switch on. If the
Switch does not light up, make sure
the Switch is connected correctly and
check the fuse.
2. If the Enable Switch is lit solidly,
then inspect all the mechanical
components in the System. With the
engine cold and the hood up, have
someone start the engine. Make sure
the transmission is in neutral and
the parking brake is set. Watch the
actuator arm on the Brake housing.
It should move forward (closed).
Whenever the accelerator pedal
is pressed, the Brake should open
(actuator arm should move back
towards the firewall).
Checking the performance of the
vacuum pump:
WARNING: The Pump must never
be run open to the atmosphere,
as this will damage the Pump
diaphragm. The Pump must
always be connected to the
Vacuum Solenoid or it’s vacuum
nipple must be plugged. The
warranty on the Pump will be
voided if the Pump is allowed to
run open to the atmosphere.
With the vehicle safely in park and
the engine off, disconnect the 5⁄ 16”
hose from the Vacuum Solenoid (Port
1, Figure 8). Connect this hose to a
vacuum gauge while keeping the other
end connected to the Vacuum Pump.
Make sure the truck is in park and
start the engine. Measure the vacuum
at 1900 RPM. The Pump should
generate a minimum of 10 psi (20.4”
Hg) of vacuum. Replace the Vacuum
pump if necessary. After testing, turn
off the engine and disconnect the
vacuum gauge and reconnect the
5⁄ 16” hose to Port 1 on the Vacuum
Solenoid.
Checking the operation of the
Exhaust Brake:
With the vehicle safely in gear, the
parking brake set, and the engine off,
disconnect the 7⁄32” hose connection
(Port 2, Figure 8) from the Vacuum
Solenoid. Connect this hose to a
vacuum tester and keep the other
end of the 7⁄32” hose connected to the
Exhaust Brake Actuator. As vacuum
is generated with the tester, the
Actuator should retract and rotate
the lever arm off it’s stop (as seen
in Figure 7). The lever arm should
travel 81.5 degrees without binding
or sticking. After testing, disconnect
the vacuum tester and reconnect the
7⁄32” hose to Port 2 on the Vacuum
Solenoid.
If the Exhaust Brake is slow to open,
check the Vacuum Solenoid’s brass
filter. If it is dirty, clean or replace it.
Replacements can be purchased from
Gale Banks Engineering or may be
found at a hardware or automotive
store.
-END SECTION 9-
97232 v.3.0
37
Notes
38
97232 v.3.0
Notes
97232 v.3.0
39
Gale Banks Engineering
546 Duggan Avenue • Azusa, ca 91702
(626) 969-9600 • Fax (626) 334-1743
Product Information & Sales: (888) 635-4565
bankspower.com
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