How to Install Exhaust Brakes

Lead Image
What You'll Need
Razor-blade cutter
Utility saw
Drill and drill bits
Wrench, torque wrench, Allen wrenches
Screwdrivers (Phillips/flat)
Socket set
Hand-held shrink blower/heater
Wire connectors (crimp style)

A remarkable way to get more miles out of each set of costly brake shoes and rotors is to affix an exhaust brake in your car's brake system. The exhaust brake is the butterfly valve which restricts the ejection of the gases coming from the engine when in use. It will also decrease an engine’s RPM through generating a back pressure within the exhaust system which lowers the compression within the engine itself. Through lessening the engine's compression, you can instantly reduce speed without utilizing the existing braking system in order to complete this job.

Step 1 - Detach Ground Connection from Your Car Battery’s Negative Post

Untie the negative post fasten from the battery with the accurate Allen or closed-end wrench. Fasten down the negative battery’s lead, further than the battery, to avoid an electric shock or electric short while setting up your car’s exhaust brake.

Step 2 - Install Exhaust Breaks

Find the factory rubber grommet which shields the plastic conduit that extends from your car’s engine compartment in the passenger compartment, via the firewall underneath the steering wheel. Employ a screwdriver to detach the grommet and dismantle its lower dashboard. Take off two screws which locked the lower dashboard towards the car then save them for re-installation. The upper section of the lower dashboard is protected by two clips you disconnect by smoothly pulling back on top of the lower dashboard’s corners.

Get the mechanized brake control box, accelerator switch, and power switch within the passenger compartment of your car. End the passenger-compartment electric wiring by linking the system to the car's fuse box. Situated at the back of the emergency brake button, the exhaust brake is wired into the suitable fuse to function properly. Mount the dashboard with the screws and factory clamps.

Step 3 - Finalize the Installation

Locate the engine’s coolant temperature sensor which runs the exhaust brake cabling that ends along its connector towards the engine. Restore the factory sensor using the exhaust brake sensor. Do not to smash the connectors. Take away the filter and factory air box to obtain access to the air box’s base plate. Untie, but do not take away, the band clamps which hold the air intake tubes towards the intake manifold, then disengage the tubes with the suitable screwdriver. Detach the intake tubes and air box in a piece then hold for reinstallation. For the reinstallation of the air box, leave the air hose ends thus they are simply reached. Power the compressor through linking its power-supply wire towards the battery junction box then attach it to the brake wiring’s harness through the complete exhaust-brake system connectors.

Step 4 - Cut the Exhaust Tubing Section

Finally, cut an existing section of the exhaust tubing big enough to contain the exhaust brake-tube body on top of the transmission cross member beneath the car. Tighten the clamps using the suitable torque so the clamps fasten the exhaust-brake tubing to its factory exhaust. Lastly, reseal the exhaust system using the complete flange gasket then tightening the projection nuts to 30 pounds of torque.