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Old 09-22-2022, 03:17 PM   #1
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Diesel Exhaust Pac-Brake solenoid trouble

On my '04 Journey, my exhaust brake is not working properly. When I turn it on, braking assistance is immediate. The problem is that it will take three to four minutes to release, which as you can imagine, is quite a problem. I purchased Pac Lube and lubricated as per their web site. I then removed the air supply fitting and replaced it with a valve, and then using air from my compressor, worked the brake several times, noticing that the unit returned to normal position instantly. So I'm assuming that the solenoid upstream is failing to release properly and I want to replace it. I've found the solenoid mounted on the frame rail, but the 12v wires seem to travel upwards and disappear into the floor above at the foot of the bed. Does anyone know where these two wires splice into something so that I'll be able to replace this properly? With the new heat-shrink waterproof splices, I'm confident that I can just splice the new wires onto the old wires right next to the solenoid, but I never do anything the easy way unless there is no other option....
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Old 09-23-2022, 05:36 PM   #2
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Was your shop compressed air set the the same pressure as the exhaust brake is receiving from the MH? More pressure would overcome restrictor plate binding from carbon and rust.
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Old 09-23-2022, 07:30 PM   #3
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My shop air was at about 80 psi. The problem is the return to normal after the air pressure should dump. Manually dumping the air immediately resets everything but the solenoid canít seem to discharge the pressure for several minutes.
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Old Yesterday, 09:49 PM   #4
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Solenoids do go bad, I've seen some that were rusted so badly inside, the plunger could barely move.
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