Banks Power Dodge Trucks: (Diesel ’98 - 02 5.9L Cummins ISB) Speed Control- Banks Exhaust Brake - Manual (Page 13)

on 1999-2002 vehicles
equipped with automatic
transmissions: Plug the
supplied wire extension
into the end of the fused
power lead. Route the
wire extension through
the firewall following the
previously installed Banks
wiring. Install the supplied
blue T-tap on the red
wire located in the wiring
harness in the engine
compartment as shown
in Figure 11 . Plug the
remaining end of the Banks
wire extension into the blue
T-tap.
36. Find an appropriate
location for the brake
activation switch on the
lower dash panel. See
Figure 12 for suggested
locations. Drill a 1⁄2” hole
through the dash panel at
this location. Note that the
backside layer of reinforcing
material may need to be
removed in the area used
to mount the activation
switch.
37. Attach the three wiring
harness leads to the switch
assembly per Figure 12 .
Remove the outer locking
ring from the shaft of the
switch assembly and install
the switch from the back
side of the dash panel with
the notch in the shaft facing
down. Slide the face plate
provided over the shaft
of the switch to indicate
switch position. Thread the
locking ring onto the shaft
of the switch body. The
depth of the switch may be
changed by adjusting the
location of the back nut on
the switch shaft.
38.
Secure the wire
loom under the dash and
hood using the nylon ties
provided.
39.
Attach the remaining
ring terminal to the metal
dash supports (suitable
chassis ground) using a
factory screw.
40. Find the OEM hose
running from the vacuum
pump/check valve just
forward of the vehicle
power steering pump.
Disconnect the 90 degree
elbow and install the brass
T-fitting as shown in Figure
13 .
41.
Cut a short length
of blue silicone hose
(approximately 2”) and push
it on to the plastic nipple
at the end of the factory
hard plastic vacuum tube.
Attach the other end of the
short silicone hose to the
T-fitting.
42. Re-attach the factory
90-degree elbow to the
outlet of the vacuum
pump/check valve. Secure all
connections with supplied
spring band clamps.
43. Use the remaining
length of blue silicone hose
to connect the vacuum
supply to the actuator
control valve and actuator.
Run a length of hose from
the brass 1⁄4”
T-fitting up to the factory
vacuum manifold on the
firewall and across the
cowl area to the previously
installed actuator control
valve.
44.
Attach the vacuum
source line to the port on
the valve labeled #1. From
the port labeled #2, run
a length of blue silicone
hose to the exhaust brake
actuator. See Figure 14 .
45.
Assemble the black
vent hose as shown and
attach this line to the port
labeled #3. Run this line
behind the exhaust brake
assembly and secure to
a convenient location.
Be sure the bronze filter
is facing down so any
collected moisture will
be drained. Secure all
vacuum lines with spring
band clamps as shown. See
Figure 14 .
46.
Secure all vacuum lines
under the hood using the
nylon ties provided. Use
care to avoid pinching the
hose closed.
Functional Testing
NOTE: The following testing
should be performed only
after the vehicle has been
allowed to COMPLETELY
COOL. This test verifies
the performance of the
warm-up feature of the
brake system and must
be performed with a cold
vehicle.
47. Verify that the Banks
Brake Activation Switch is
in the “oFF” position.
48. Ensure that the
accelerator pedal is not
depressed. Turn the
ignition key to the “on”
position. The green LED
on the Computerized Brake
Controller (CBC) should light
up.
49.
Slowly press the
accelerator pedal. The
green LED should turn off
almost immediately (very
little throttle movement).
Release the accelerator
pedal and the green
LED should again light
up. Repeat this cycle a
few times to verify CBC
function.
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