Pacbrake C44059 User manual

C44059, C44061, C44063, C44065
PRXB EXHAUST BRAKE
HIGH PERFORMANCE
APPLICATION
1994 - 2002 DODGE RAM AUTOMATIC TRUCKS EQUIPPED WITH
47RE TRANSMISSIONS WITH 5.9L, 24 VALVE CUMMINS DIESEL ENGINES

INSTALLATION MANUAL - INSERT TITLE HERE, L1234
PG 1
INSTALLATION MANUAL - C44059 / C44061 / C44063 / C44065, L5855
PG 1
GETTING STARTED
Thank you and congratulations on your purchase of a Pacbrake exhaust retarder.
Before starting the install, please read the entire installation manual carefully and be sure you have a full understanding of
the installation. Check that your Pacbrake kit is correct for the application and contains all the necessary parts.
ADDITIONAL MOUNTING GROUP REQUIRED
Vehicles with aftermarket exhaust systems require a di󰀨erent mounting group.
▪Vehicles with a 3"exhaust and an HX 35 turbo, use Pacbrake Part # C11440
▪Vehicles with a 3.5"aftermarket exhaust and a 5 bolt HX 35 turbo outlet, use Pacbrake Part # C11420
▪Vehicles with a 4" aftermarket exhaust and an HX 40 or equivalent turbo with a half marmon ange, use Part # C11400
Pacbrake C44059 Kit is a high performance PRXB exhaust brake designed
to provide maximum retarding throughout the RPM range of your 1994-1995
Dodge 12 valve Cummins with an automatic 47RH transmission.
Heavy duty exhaust valve springs ARE MANDATORY for all 12 valve engines.
Pacbrake C14010 Spring Kit is included in the C44059 Kit.
Failure to install the heavy duty springs WILL result in engine damage!
Pacbrake C44061 Kit is a high performance PRXB exhaust brake designed
to provide maximum retarding throughout the RPM range of your 1996-1998
Dodge 12 valve Cummins with an automatic 47RE transmission.
Heavy duty exhaust valve springs ARE MANDATORY for all 12 valve engines.
Pacbrake C14010 Spring Kit is included in the C44061 Kit.
Failure to install the heavy duty springs WILL result in engine damage!
Pacbrake C44063 Kit is a high performance PRXB exhaust brake designed to
provide maximum retarding throughout the RPM range of your 1998½ Dodge
24 valve Cummins with an automatic 47RE transmission.
Installation of heavy duty exhaust valve springs is NOT REQUIRED on
24 valve engines.
Pacbrake C44065 Kit is a high performance PRXB exhaust brake designed
to provide maximum retarding throughout the RPM range of your 1999-2002
Dodge 24 valve Cummins with an automatic 47RE transmission.
Installation of heavy duty exhaust valve springs is NOT REQUIRED on
24 valve engines.

INSTALLATION MANUAL - INSERT TITLE HERE, L1234
PG 2
INSTALLATION MANUAL - C44059 / C44061 / C44063 / C44065, L5855
PG 2
1Remove the lower dash panel and locate an ignition power supply
at the base of the steering column.
1994-1997 models use a medium blue 14 gage wire and
blue “T” tap.
1998-2002 models use a black with orange tracer 18 gage wire
and a red “T” tap.
Check the wire with a voltmeter to ensure it is 12 volts and an
ignition power source. Attach the supplied “T” tap to this wire and
insert the red 16 gage 3 amp fused wire to this “T” tap.
2Mount the Pacbrake control unit to the provided bracket on the inside
of the rewall (under the dash - as shown in the photo) using the
factory stud and nut for the steering column. Once the Pacbrake
control unit is fastened to the stud, connect the grey and black
connectors of the harness to the Pacbrake control unit.
Secure the harness with the provided tie-straps.
3 Locate the plastic plate in the drivers side of the rewall. Drill a hole
large enough to feed the Pacbrake harness through. Then, feed the
harness into the engine compartment from the cab side.
Apply silicon sealant around the loom to provide a seal.
4ON/OFF SWITCH INSTALLATION: ALL KITS
Provided on the last pages of this manual are 2 templates for dash
switch locations. The 2 switch locations are suggestions only for
specic years.
Consult the customer for their preference before drilling a ¼"
hole to accommodate the dash switch!
Install the dash switch and route the wires to the control unit. Secure
the wires with the supplied tie-straps. At the control unit, locate the
matching wire colors and connect them using the supplied heat
shrinkable red butt connectors. Once crimped, heat the connector to
provide a water tight seal.
Re-install the lower dash panel.
1
C44059, C44061, C44063 & C44065 ELECTRICAL INSTALLATION
2
3
4

INSTALLATION MANUAL - INSERT TITLE HERE, L1234
PG 3
INSTALLATION MANUAL - C44059 / C44061 / C44063 / C44065, L5855
PG 3
5Route the black wire with the eye terminal to the negative battery
terminal or a good chassis ground. Secure with the supplied tie-
straps.
Remove both the positive battery terminals. Route the red fused wire
with the eye terminal to the positive battery terminal (leaving the
positive lead disconnected).
The battery leads are connected in Step 18.
6 Route the remaining harness along the rewall to the passenger
side and then route it forward along the fender to the passenger
side battery. Make sure it is secured away from heat sources and
moving parts using the supplied tie-straps.
C44063 & C44065 kits proceed to Step 8.
7THROTTLE SWITCH INSTALLATION: C44059 & C44061 KITS ONLY
Locate the stud (shown in the photo) and remove the nut. Install the
switch assembly with the switch arm horizontal. Re-install the stud nut
and tighten, making sure the switch arm is behind the accelerator
lever.
Adjust the switch by loosening the screws and positioning it to “click”
just as the throttle returns to its released position. Cycle the throttle
and listen for the “click” each time the throttle returns to idle. Tighten
the screws when adjustment is complete.
Locate the black and white wires of the Pacbrake harness originating
at the control unit. Attach the black wire to the terminal connected
to the diode on the throttle switch. Connect the white wire to the other
terminal on the throttle switch. Make sure it is secured away from
heat and moving parts using the supplied tie-straps. Consult the
wiring schematic pertaining to your kit #, found on page 9-11.
5
6
7

INSTALLATION MANUAL - INSERT TITLE HERE, L1234
PG 4
INSTALLATION MANUAL - C44059 / C44061 / C44063 / C44065, L5855
PG 4
8C44063 & C44065 KITS ONLY:
Under the hood, beside the fuel lter, locate the factory 3 pin
Weather- Pac connector on the driver side of the engine (shown
by the arrow). Remove the protective cap and install the mating
connector in the Pacbrake harness. Install the removed protective
cap on the unused connector on the Pacbrake harness - unless
you have a performance module connected to it. If so, it connects
to the Pacbrake connector.
NOTE: Some 1999 model year trucks and all 1998½ will require
the use of a 3 pin triangular jumper harness to connect to the data
link connector. See schematic pertaining to your kit #, found on page
9-11. Proceed to Step 10.
9C44061 KIT ONLY:
Locate the diagnostic connector under the dash on the drivers side.
Connect the male plug of the Pacbrake harness to the factory
diagnostic connector. Secure the Pacbrake connector to the
diagnostic connector using the supplied tie straps.
10 C44061, C44063 & C44065
Remove the air lter housing to access the passenger side rewall
and locate the PCM (shown in g 10A). Remove the C2 and C3
connectors. Remove the plastic cover to access the wires. Pull back
the conduit to give access for attaching wires into the factory harness.
Use g 10B as a guide to the pin locations.
C2 CONNECTIONS
Locate the orange/black wire in pin 11 of the C2 connector. Cut this
wire. Attach the brown wire of the Pacbrake harness to the PCM side.
Attach the orange wire to the harness side of the orange/black wire.
These connections are done using the supplied red heat shrinkable
butt connectors.
Locate the brown wire in pin 21 of the C2 connector. Cut this wire and
splice the blue wire of the Pacbrake harness into it using the supplied
red heat shrinkable butt connectors.
C3 CONNECTIONS
Locate the orange/white wire in pin 13 of the C3 connector. Cut this
wire and splice the yellow wire of the Pacbrake harness into it using
the supplied red heat shrinkable butt connectors.
Using the heat gun, heat the connectors to provide a water tight seal
on all heat shrinkable butt connectors. See the wiring diagram
pertaining to your kit #, found on page 9-11.
PCM AND TRANSMISSION CONNECTIONS
8
9
10
A
10
B
C1
C2C3 C1
C2C3
22
12
1
32
21
11
Powertrain Control
Module C2 (Diesel)
22
12
1
32
21
11
Powertrain Control
Module C3 (Diesel)
POWERTRAIN
MODULE C2
(DIESEL)
POWERTRAIN
MODULE C3
(DIESEL)

INSTALLATION MANUAL - INSERT TITLE HERE, L1234
PG 5
INSTALLATION MANUAL - C44059 / C44061 / C44063 / C44065, L5855
PG 5
11A C44059 KITS ONLY:
Route the brown, orange, blue, yellow and the OBD1 connector of the
Pacbrake harness along the rewall to the passenger side rewall.
Locate the factory OBD1 connector and apply electrical tape to
secure them together.
Remove the air lter housing to gain access to the PCM.
11B C44059 KITS ONLY:
On the passenger side rewall, locate the PCM (shown in g 11A).
Remove the connector by loosening the bolt in the center. Remove
the plastic cover to access the wires. Pull back the conduit to give
access for attaching wires into the factory harness. Use g 11B as a
guide to the pin locations.
Locate the orange/black wire in pin 54 of the PCM connector. Cut this
wire. Attach the brown wire of the Pacbrake harness to the PCM side.
Attach the orange wire to the harness side of the orange/black wire.
These connections are done using the supplied red heat shrinkable
butt connectors.
Locate the brown wire in pin 55. Cut this wire and splice the blue wire
of the Pacbrake harness into it using the supplied red heat shrinkable
butt connectors.
Locate the orange/white wire in pin 10. Cut this wire and splice the
yellow wire of the Pacbrake harness into it using the supplied red
heat shrinkable butt connectors.
See wiring diagram pertaining to your kit #, found on page 9-11.
12 Consult with the customer for their preferred location to mount the
quick disconnect for the airline. The mounting location should be in
a clean, dry area with easy access to the operator.
Using the two self tapping screws mount the “L” bracket. Insert the
bulkhead airline tting into the “L” bracket and tighten the jam nut to
secure it. Apply thread sealant to prevent air leaks.
Follow the airline installation procedures in the next step.
11
A
11
A
11
B
Connector view shown is of the
PCM side, connector removed.
12
41
21
1
60
40
20
POWERTRAIN
CONTROL
MODULE

INSTALLATION MANUAL - INSERT TITLE HERE, L1234
PG 6
INSTALLATION MANUAL - C44059 / C44061 / C44063 / C44065, L5855
PG 6
13 Shown in the photo is a suggested location marked “A”.
Connect one end of the remaining air line into the quick
connect assembly and route this to the remaining tting at the
compressor.
Mount the air inlet lter in a cool, dry location. A suggested
location is shown in the photo, marked with a “B”. Locate the
blue nylon airline provided and route to the lter housing. Route
the other end to the compressor inlet tting located on the
compressor body (the compressor is installed in next step).
Make sure the nylon hose is cut square on each end and is
pushed into the ttings until it clicks.
14 Remove the passenger side battery.
Place the compressor and bracket assembly into the battery
box (as shown in the photo). Place and secure the battery
on top of the compressor bracket. Reinstall the hold down
assembly. Connect the corresponding weather pac connectors
of the Pacbrake harness to the compressor.
Do not connect the battery cables at this time.
15 Install the 90° tting in the top of the tank and the provided hex
plug (or drain valve if desired) into the bottom (as shown in the
photo). Use thread sealant on all ttings to prevent air leaks.
The air tank requires 2 - 5/16" holes on a 3¼" center.
For fastening to the frame, use one of the pre-existing holes
in the frame and drill the second hole. Using the fasteners
provided, mount the air tank on the outside of the frame.
Connect the nylon airline to the air tank and route the other end
to the tting at the solenoid and connect.
A
B
13
14
15

INSTALLATION MANUAL - INSERT TITLE HERE, L1234
PG 7
INSTALLATION MANUAL - C44059 / C44061 / C44063 / C44065, L5855
PG 7
Connect to
quick connect
Connect to air
intake lter
Connect to
exhaust brake
Connect to
air tank
16 Compressor & Airline Routing
17 Exhaust Brake Installation
NOTE: Vehicle must have aftermarket header pipe, that mounts directly to the turbo outlet ange.
Must not have factory cast elbow. Follow L5669 Installation Addendum included
NOTE: 12 Valve engines REQUIRE H.D. exhaust valve springs to be installed.
Contact Pacbrake Customer Service @ 800.663.0096 for installation procedure, if required.
18 Using the nylon airline provided connect the solenoid valve port
marked “CYL” to the air cylinder.
Reconnect both positive battery terminals with the positive lead
of the Pacbrake harness. Reconnect both negative battery
terminals. Connect the black wire (Pacbrake ground) to the
negative battery terminal.
Secure all electrical harnesses and nylon airlines with the
supplied tie-straps.
18

INSTALLATION MANUAL - INSERT TITLE HERE, L1234
PG 8
INSTALLATION MANUAL - C44059 / C44061 / C44063 / C44065, L5855
PG 8
TESTING THE SYSTEM - C44059, C44061, C44063 & C44065
With the Pacbrake switch in the OFF position, start the engine and allow to idle. The Pacbrake compressor should
pump air for approximately 2 minutes (this will ll the air tank from empty). Once the Pacbrake control unit conrms
the air tank has reached maximum air pressure, the control unit will perform a Self Test Cycle which will activate and
release the exhaust brake two times with the vehicle stationary.
Vehicles with 47RH/RE transmissions which have aftermarket valve bodies and aftermarket lock-up torque convert-
ers which are able to hold lock-up during exhaust braking in 1st and 2nd gears can use the later 48RE programming.
To change the existing program within the Pacbrake control unit, simply locate the orange wire with a spade con-
nection approximately 6 inches from the control unit. Disconnect this connection. Turn the ignition ON. The exhaust
brake should cycle 3 times conrming the 48RE program has been loaded. This di󰀨erence between the two pro-
grams is that the 48RE transmission will allow exhaust braking in 2nd and 1st gears, where the factory 47RH/RE
transmission will not.
Test drive the vehicle. If lock-up will not hold during exhaust braking in 2nd or 1st gear, re-connect the orange wire.
LED SWITCH OPERATION
RED - Brake enabled and ready for activation
GREEN - Parameters are achieved, and the Pacbrake controller is now commanding torque converter lock-up
ORANGE - Brake currently active
No Illumination - Brake disabled/OFF
FEATURES - C44059, C44061, C44063 & C44065
The Pacbrake control unit has a built in warm-up feature. This feature will activate the exhaust brake at idle with the
vehicle stationary when the Pacbrake switch is turned ON. When the coolant temperature reaches 170°F or 75°C,
the control unit will disable the warm-up feature at idle. When performing a road test, the O.D. (overdrive) switch
must be in the OFF position and the Pacbrake switch in the ON position. Attain road speed above 40 MPH or 65km/h
and release the accelerator pedal. The exhaust brake should apply, slowing the vehicle. Once the exhaust brake has
brought the vehicle’s engine speed below 900 RPM, the exhaust brake will disengage. When using the auxiliary coil
hose for ination, the Pacbrake switch must be turned ON with the engine running.

INSTALLATION MANUAL - INSERT TITLE HERE, L1234
PG 9
INSTALLATION MANUAL - C44059 / C44061 / C44063 / C44065, L5855
PG 9
ELECTRICAL SCHEMATIC:
C44059 1994-1995 12 VALVE ENGINES, AUTOMATIC TRANSMISSION ONLY
Transmission
Soleniod
Connector
Driver’s Side Battery
+
Pos.
Neg.
-
Cut Here
30 Amp
Inline Fuse
Compressor
Connector
Connector
A B
Orange Pin 13
Black
Grey
Red Red
Pin 23 Pin 1 8
Pacbrake
Control Unit
Br o wn
Brown
Orange Pin
Blue Brown Pin 4
5Pin 6
Pin
Pin 1 5
Pin 16
Pin 1 9
Black
White
Black
Pin 24
22
1
27
8
36
45
Orange/Black
Orange/White Orange/White
Yellow
Red
Grey
kcalB
Red
3 Amp Fuse
Yellow
Orange
Pin 9
Pin 1 0
Orange
Ignition Power Source
PIN 54
PIN 55
PIN 1 0
Orange
O BD I
Plug
41
21
1
60
40
20
POWERTRAIN
CONTROL
MODULE
Throttle
Switch
Pacbrake
Switch
Pin 1
Black Pin 2
White
Green
Exhaust
brake
Pin 21
Pin 14
Red
Splice
Pressure
Switch
Pacbrake
Solenoid
Air Inlet Port
To Air Tank
To Cylinder
To Battery
(negative)
Red
Black
To Quick
Connect
Blue
Blue
Diode

INSTALLATION MANUAL - INSERT TITLE HERE, L1234
PG 10
INSTALLATION MANUAL - C44059 / C44061 / C44063 / C44065, L5855
PG 10
ELECTRICAL SCHEMATIC:
C44061 1996-1998 12 VALVE ENGINES, AUTOMATIC TRANSMISSION ONLY
Pacbrake
Switch
Pin 1
Black Pin 2
White
Green
Exhaust
brake
Pin 21
Pin 14
Red
Splice
Splice
Brown
Transmission
Soleniod
Connector
Driver ’s Side Battery
+
Pos.
Neg.
-
Cut Here
22
12
1
22
12
1
32
21
11
32
21
11
30 Amp
Inline Fuse
Compressor
A B
Orange Pin 13
Black
Grey
Red Red
Pin 23
Pin 18
Pacbrake
Control Unit
Bro wn
Blue Brown
Orange
Pin
Pin 4
5
Pin 6
Powertrain Control
OBD II Plug
Module C2 (Diesel)
Pin
Pin 15
Pin 16
Pin 19
Black
White
Black
niP 24
22
1
27
8
36
45
Orange/Black
Orange with
White Wire
Pin 15
Pin 7
Red
Grey
kcalB
Red
Powertrain Control
Module C3 (Diesel)
3 Amp Fuse
Green
Yell o w
Pin 8
Pin 7
Orange
Ignition Power Source
PIN 13
Orange
Orange with White Wire
Yellow
Pressure
Switch
Blue Blue
Red
Orange
To Quick
Connect
Throttle
Switch
Air Inlet Port
Pacbrake
Solenoid
To Cylinder
Connector
To Battery
(negative)
To Air Tank
Connector
Diode

INSTALLATION MANUAL - INSERT TITLE HERE, L1234
PG 11
INSTALLATION MANUAL - C44059 / C44061 / C44063 / C44065, L5855
PG 11
ELECTRICAL SCHEMATIC:
C44063 & C44065 1998½ - 2002 24 VALVE ENGINES, AUTOMATIC
TRANSMISSION ONLY
Pin19
Pin24
Jumper Switch
Transmission
Soleniod
Connector
Driver ’s Side Battery
+
Pos.
Neg.
-
Cut Here
30 Amp
Inline Fuse
Compressor
A B
Orange Pin 13
Black
Grey
Pin 23
Pin 18
Pacbrake
Control Unit
Bro wn Orange Pin 5 Pin 6
Pin 22
1
27
8
36
45
Orange/Black
Brown
for ’98½-’99 Model
Year Trucks
Red
Grey
kcalB
Red
3 Amp Fuse
Pin B
Pin A
Green
Yell o w
Pin 11
Pin 12
Orange
Diagnostic Connector
Ignition Power Source
Pin 7
Powertrain Control
Module C2 (Diesel)
Powertrain Control
Module C3 (Diesel)
22
12
1
32
21
11
22
12
1
32
21
11
Connector
Connector
Pin 13
Orange with
White Tracer
Orange with White Tracer
Pin 4
Blue
Yellow
Pin 15
Pacbrake
Switch
Pin 1
Black Pin 2
White
Green
Exhaust
brake
Pin 21
Pin 14
Red
Splice
Splice
Pressure
Switch
To Quick
Connect
Air Inlet Port
Pacbrake
Solenoid
To Cylinder
To Battery
(negative)
To Air Tank
Red
Orange
Connector
Blue Blue
L5855_REV10.10.15.2018

1/2" Drill
Hood release handle cut-out
Flush with edge of panel
Flush with center of screwhole
Cut out template along outer edge and align as shown.
DODGE RAM
DASH SWITCH TEMPLATE
MODEL YEARS 1994-1998
For C44072 and C44074 kits
NOT using a shifter switch
1/4" Drill For C44073, C44075
and C44076 kits
Flush with center of screw hole
1/4" Drill - For C44059, C44061
C44063 and C44065 kits
Flush with edge of panel
Hood release handle cut-out
Cut out template along outer edge and align as shown
DASH SWITCH TEMPLATE
1994-1998

1/2" Drill
1/2" Drill
Flush with edge of panel
NOTE: Template location is
only a suggestion. Access
to back of this location is
dicult and wires must be
installed onswitch terminals
prior to installation.
Cut out template along outer edge and align as shown.
Align with bottom of dash bezel
Cigarette Lighter
* Alternate Location
At Bottom Of Page 1/4" Drill
For C44073, C44075
and C44076 kits
For C44072 and C44074 kits
NOT using a shifter switch
or 1/4" Drill
Cut out template along outer edge and align as shown
NOTE: Template location is
only a suggestion. Access
to back of this location is
di󰀩cult and wires must be
installed on switch terminals
prior to installation.
DASH SWITCH TEMPLATE
1999-2002
1/4" Drill
For C44059, C44061,
C44063 and C44065 kits