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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 09-24-2022, 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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Old 09-28-2022, 04:25 PM   #5
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I'm confused. You say it takes 3or 4 minutes to release. Three or four minutes after what?

On my 03' if I turn my exhaust break on it stays on (even if I turn it off) until I press on the throttle. If I leave it on then it releases on throttle then reengages once I release he throttle.
I've never read up on how it should work, maybe I should.

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Old 09-28-2022, 04:41 PM   #6
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If I apply throttle after it is engaged I get zero power and clouds of black smoke for minutes. Same as just turning it off.
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Old 09-28-2022, 06:38 PM   #7
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Quote:
Originally Posted by dickb46 View Post
I'm confused. You say it takes 3or 4 minutes to release. Three or four minutes after what?

On my 03' if I turn my exhaust break on it stays on (even if I turn it off) until I press on the throttle. If I leave it on then it releases on throttle then reengages once I release he throttle.
I've never read up on how it should work, maybe I should.

dick
"Three to four minutes after what"?
What I'm assuming he means is, if he wants to cease operations of his exhaust brake, he then steps on the accelerator and that should IMMEDIATELY stop the exhaust brake from working. But, in his case, even though he steps on the accelerator to try and power up, the exhaust brake is still activated, not good! That could be dangerous in some situations. And like Ray stated, it's more than likely the solenoid that's the fault here.

I have no idea where the wires from the solenoid go to. WE have a very close sister ship to his. We have an '04 Itasca Horizon 36GD with the CAT C-7 330HP and also have the Jacobs Pac-brake (exhaust brake). I'd have to find the chassis wiring diagram in my DTNA set of plans to help find where the wires lead to from the solenoid. Can't be too hard to trace them down.
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Old 09-28-2022, 11:09 PM   #8
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Left field idea>
Using the part number search does it say anything about how long the pig tail is?
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Old 09-29-2022, 07:37 PM   #9
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Solenoid comes with 18Ē of 18 AWG wire, and I can see about 12Ē underneath. Iím thinking that itís spliced in an inaccessible location, so heat shrink it is!
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