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6333 P/N 26275A Eng. Installation
Manual
For '99 Dodge Ram Trucks with the
Cummins ISB5.9 Engine
Bulletin 3401750
P/N 026275A
Jacobs Exhaust Brake
2
JACOBS EXHAUST BRAKE FOR '99 DODGE RAM WITH ISB5.9 ENGINE - INSTALLATION MANUAL
Table of Contents
Section 1: Installing the Brake Assembly: ...................... 3
Section 2: Installing the Pneumatic Group ..................... 5
Section 3: Installing the Wire Harnesses ........................ 7
Section 4: Dashboard Switch Installation ........................ 9
Section 5: Operational Check....................................... 11
Section 6: Troubleshooting .......................................... 11
Appendix 1: Mounting Templates ................................. 13
Introduction
The procedures for installing the brake system are
organized into five main sections, with each section
detailing the installation of related components. We
strongly recommend that you perform the procedures in
the order in which they are presented. The last section lists
troubleshooting procedures, in case you are experiencing
problems with the exhaust brake.
For additional information or technical support, contact
Cummins Customer Assistance Center by calling
1-800-DIESELS (1-800-343-7357).
Application Notes
The Jacobs Exhaust Brake has been specifically
engineered to fit your '99 Dodge Ram truck equipped with
the Cummins ISB5.9 Turbo Diesel engine. All parts are
included in the kit, allowing installation without requiring
any fabrication. In addition, all 99 model year trucks have
the Engine Control Module (ECM) preprogrammed for
exhaust brake operation, so no ECM recalibration is
required.
Special Tools and
Materials Required
You should have the following tools and materials before
you begin this installation:
Rust penetrant, such as Liquid Wrench® or Mopar
P/N 4318039
Silicone sealer
Anti-seize compound
Battery terminal puller
Common hand tools such as metric wrenches and
screwdrivers
Torque wrenches
Drill with 1/4, 1/2, #56 and #27 (0.144) bits
Knife or other tool for cutting the rubber vacuum hose
Clean shop towels
Teflon® pipe sealant
Loctite® 242 or equivalent
Safety Precautions
The following symbols in this manual signal conditions
potentially dangerous to the mechanic or equipment.
Read this manual carefully. Know when these
conditions can exist. Then take necessary steps to
protect personnel as well as equipment.
THIS SYMBOL WARNS OF POSSIBLE
PERSONAL INJURY.
THIS SYMBOL REFERS TO POSSIBLE
EQUIPMENT DAMAGE.
NOTE: INDICATES AN OPERATION, PROCEDURE OR
INSTRUCTION THAT IS IMPORTANT FOR CORRECT
SERVICE.
Fuels, electrical equipment, exhaust gases and
moving engine parts present potential hazards that
could result in personal injury. Take care when
installing equipment or parts. Always wear safey
glasses. Always use correct tools and follow proper
procedures as outlined in this manual.
Cummins Engine Company, Inc.
Box 3005
Columbus, IN 47202-3005
U.S.A.
Printed in U.S.A. 6/98
©1998 Cummins Engine Company, Inc. and
Jacobs Vehicle Systems, Inc. JACOBS EXHAUST BRAKE FOR '99 DODGE RAM WITH ISB5.9 ENGINE - INSTALLATION MANUAL
3
Show stock elbow bolted to bottom of turbo unit.
NEW PHOTO!
Section 1: Installing the Brake Assembly
Fig. 1
Fig. 2
Figure 2
1. Preparation.
Use a battery terminal puller to disconnect the
negative () leads from both batteries.
NOTE: WHEN YOU DISCONNECT THE BATTERIES, THE
MEMORY FOR THE CLOCK AND THE STATION
PRESETS ON THE RADIO WILL BE LOST. YOU MAY
WANT TO RECORD THE RADIO STATION PRESETS
ON PAPER BEFORE YOU DISCONNECT THE
BATTERY.
2. Remove the Air Filter Box from the vehicle.
a. Use a screwdriver to loosen the clamp and disconnect
the large plastic duct that connects the air filter box to
the turbocharger at the turbocharger end (see Fig. 1).
b. Remove the air filter housing and duct hose as an
assembly (see Fig. 2). Gently lift air filter housing from
the inner fender. The plastic connectors will remain in
the air filter housing and the steel mounting studs will
remain in the inner fender.
3.
Remove the existing exhaust elbow that mounts
to the rear of the turbocharger.
a. Remove the two bolts that attach the exhaust pipe to
the exit side of the elbow (located at the position of the
arrow in Figure 3). Spray rust penetrant on bolts before
loosening.
Fig. 3 4
JACOBS EXHAUST BRAKE FOR '99 DODGE RAM WITH ISB5.9 ENGINE - INSTALLATION MANUAL
b. Loosen and remove the 5 capscrews that attach the
elbow to the exhaust side of the turbocharger (Fig. 4).
This will allow you to remove the elbow and gasket
from the vehicle.
4.
Attach the Turbo Adapter Plate to the
Turbocharger.
a. Install the turbo outlet adapter supplied in the kit with
the new metal gasket and capscrews.
5.
Attach the Brake Assembly to the Turbocharger.
a. Attach one end of the supplied 30" length of 1/4"
vacuum hose to the fitting on the exhaust brake
actuator. Use a hose clamp on this connection.
b. The supplied gasket is used between the turbo
adapter plate and the exhaust brake housing. This
gasket is adhesive-backed to ease installation. Clean
the gasket surfaces of the turbo outlet and the exhaust
brake assembly, making sure the surfaces are free of
dirt, grease, and oils. Remove the paper backing and
adhere the gasket to the top of the brake housing
opening.
c. Attach the brake housing to the turbocharger, using
the V clamp supplied in the kit (Fig. 5). As you line up
the two components, be careful not to knock the
gasket out of place. Before you tighten the V clamp,
rotate the brake housing so that the two holes in the
mounting flange are horizontal as shown in Figure 6.
d. Tighten the V clamp to 72 in.-lb of torque.
6.
Attach the exhaust pipe to the bottom of the
exhaust brake housing.
Apply an anti-seize compound to the original two bolts
that held the original elbow in place and tighten them
to 19 ft-lb of torque.
NOTE: SINCE THE EXHAUST BRAKE ASSEMBLY DOES NOT
EXTEND AS FAR FROM THE TURBOCHARGER AS
THE STOCK ELBOW, YOU MAY NEED TO MOVE THE
EXHAUST PIPE FORWARD SLIGHTLY TO ENGAGE
THE MOUNTING BOLT THREADS IN THE EXHAUST
BRAKE ASSEMBLY. TO ACCOMPLISH THIS, IT MAY
BE HELPFUL TO HAVE AN ASSISTANT PUSH ON THE
EXHAUST SYSTEM TAILPIPE AS YOU TIGHTEN THE
MOUNTING BOLTS.
Fig. 5
Fig. 6
brake on turbo arrows showing horizontal orientation of
flange
brake housing mounted on turbo
Fig. 4 JACOBS EXHAUST BRAKE FOR '99 DODGE RAM WITH ISB5.9 ENGINE - INSTALLATION MANUAL
5
Section 2 - Installing the Pneumatic Group
BE CERTAIN TO TORQUE ALL VACUUM
FITTING HOSE CLAMPS TO 72 IN.-LB.
1.
Drill Mounting Holes.
a. In the engine compartment, cut away about 8 of
insulation from the upper right (passenger) side of the
plenum (Fig. 7).
NOTE: THERE MAY BE A PLUGGED HOLE ON THE PLENUM
IN THE AREA EXPOSED WHERE THE INSULATION
WAS REMOVED. IF THIS IS TRUE FOR YOUR
VEHICLE, REMOVE THE PLUG AND COVER THE
HOLE WITH SILICONE SEALER. THE PLUG MUST BE
REMOVED AS IT MAY INTERFERE WITH THE
SOLENOID MOUNTING PLATE INSTALLATION.
b. Appendix 1 of this manual contains a template used to
locate mounting holes in the vehicle's plenum. Cut out
the template along the solid lines.
c. Orient the template on the plenum, using the
guidelines indicated on the template (refer to Figure 8).
Place the template so that the upper part of the
template fits against the corresponding contour of the
plenum.
d. Using the template, centerpunch hole locations on the
plenum and verify that they match the template. Drill a
pilot hole with a #27 drill in the centerpunched
locations, then drill to final size with a 1/2" drill.
2.
Attach Pneumatic Controls.
a. Insert the four supplied well nuts into the 1/2 holes
drilled into plenum.
b. Attach the hose fittings to the solenoid (see Fig. 9). Be
sure to orient the 90° fitting with the outlet pointing
toward the vacuum solenoid body, as shown in
Figure 9.
NOTE: USE PIPE SEALANT ON ALL NPT (PIPE THREAD)
CONNECTIONS.
Fig. 8
Fig. 7
Fig. 9 6
JACOBS EXHAUST BRAKE FOR '99 DODGE RAM WITH ISB5.9 ENGINE - INSTALLATION MANUAL
c. Insert the isolator grommets into the large holes in the
Solenoid Mounting Plate as indicated in Figure 10.
d. Note the orientation of the mounting plate in Figure 10.
The distance from the end of the plate to the raised
area in the center of the plate is greater on one side
than the other. The side with the greater distance is
the left side of the plate when the raised portion is
facing toward you (when installed, this side points
toward the passenger side of the vehicle). Holding the
plate in this orientation, insert one M6 x 40 mm screw,
washer, and lockwasher into the isolator grommet in
the lower left corner of the plate. See Figure 10 for
correct orientation of these attaching parts.
NOTE: THIS BOLT MUST BE INSERTED BEFORE ATTACHING
THE SOLENOID, SINCE THERE WILL NOT BE
SUFFICIENT CLEARANCE TO INSERT THE BOLT
AFTER THE SOLENOID ASSEMBLY IS MOUNTED TO
THE PLATE.
e. Attach the Vacuum Solenoid to the mounting bracket
using the two #8-32 screws supplied in the kit, using
Loctite® 242 on the screw threads. Refer to Fig. 9 for
proper orientation of the solenoid on the bracket.
f. Attach the mounting bracket to the plenum using the
three remaining M6 x 40 screws, washers and lock
washers.
3. Connect the Vacuum Actuator on the exhaust
brake assembly to the 2 side of the