BD Diesel Performance 1030395 Installation Manual

22 September 2015 PN#1030395 TorqLoc (I-00208)

BD Engine Brake Inc.

Plant Address: 33541 MacLure Rd. Abbotsford, BC, Canada V2S 7W2

U.S. Shipping Address: 88-446 Harrison St, Sumas, WA 98295 U.S. Mailing Address: P.O. Box 231, Sumas, WA 98295

Phone: [phone] | Fax: [phone] | Internet: www.bd-power.com

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Torque Convertor Control System

Part# 1030395

Installation Manual for the following applications:

BD Brakes for Dodge, Ford and Chevrolet

Pac Brake for Dodge & Ford

Jacobs E-Brake for 1994-98 Dodge 6BTA 12 Valve

* Please read this instruction manual before starting installation *

22 September 2015 TorqLoc# 1030395

BD Engine Brake Inc.

Plant Address: 33541 MacLure Rd. Abbotsford, BC, Canada V2S 7W2

U.S. Shipping Address: 88-446 Harrison St, Sumas, WA 98295 U.S. Mailing Address: P.O. Box 231, Sumas, WA 98295

Phone: [phone] | Fax: [phone] | Internet: www.bd-power.com

2

T A B L E O F C O N T E N T S

WELCOME ........................................................................................................................................................................ 2

The BD TORQLOC Advantage ......................................................................................................................................... 2

Operating the BD TORQLOC ............................................................................................................................................ 3

Transmission Quirks ......................................................................................................................................................... 4

Compatibility With Other Exhaust Brake Brands ............................................................................................................... 4

Adjusting For Application ................................................................................................................................................... 5

Wiring the TORQLOC (with an exhaust brake) ................................................................................................................. 5

Testing The TORQLOC (with an exhaust brake) .............................................................................................................. 9

Testing the TORQLOC (without an exhaust brake) ........................................................................................................ 11

Dodge “TRANS” Relay Bypass (1996-2000) ................................................................................................................... 12

BD TORQLOC WIRING DIAGRAMS - ........................................................................................................................... 13

∙ BD BRAKES: 1995-2003 FORD 7.3L / 1999-2005 DODGE 24V .................................................................................. 13

∙ BD BRAKES: 1994-1998 DODGE / 1988-94 FORD IDI / CHEVY 6.2-6.5L .................................................................. 14

∙ PAC BRAKE: DODGE 12V ........................................................................................................................................... 14

∙ PAC BRAKE: 1995-97 FORD POWERSTROKE .......................................................................................................... 15

∙ JACOBS E-BRAKE: DODGE 12 Valve ........................................................................................................................ 16

∙ PAC BRAKE: DODGE ISB 24 VALVES ........................................................................................................................ 17

∙ JACOBS BRAKE: DODGE ISB 24 VALVES ................................................................................................................. 17

∙ US GEAR D-CELERATOR BRAKES ............................................................................................................................ 17

∙ NO EXHAUST BRAKE INSTALLED ............................................................................................................................. 17

AUTOLOC vs. TORQLOC .............................................................................................................................................. 18

Questions? ...................................................................................................................................................................... 19

WELCOME

Thank you for purchasing the BD TorqLoc Kit. This manual is to aid you with your
installation and operation of the unit. We strongly suggest that you retain this
manual for any future reference.

NOTE: For trucks with a Jacobs Exhaust Brake system for the Dodge ISB 24
valve application, and all US Gear D-Celerators, this brake cannot be hooked

up to the module. Follow the instructions that are for “Without Exhaust

Brake” on page 10.

The BD TORQLOC Advantage

Exhaust brake usage can cause high temperatures in the automatic transmission
due to torque convertor slippage if a lockup device is not used. Only 10% to 80% of
the retarding force is transferred through the fluid coupling of most torque
convertors.

The BD TorqLoc commands the lock-up clutch of the torque convertor to stay
engaged when the BD Exhaust Brake is activated. This allows up to 100% of the
retarding force to be transferred while in 3rd and 4th gear. Also, transmission oil
temperatures will remain low because of little or no slippage occurring in the
convertor in these gears.

22 September 2015 TorqLoc# 1030395

BD Engine Brake Inc.

Plant Address: 33541 MacLure Rd. Abbotsford, BC, Canada V2S 7W2

U.S. Shipping Address: 88-446 Harrison St, Sumas, WA 98295 U.S. Mailing Address: P.O. Box 231, Sumas, WA 98295

Phone: [phone] | Fax: [phone] | Internet: www.bd-power.com

3

Operating the BD TORQLOC

The TorqLoc works off of a lighted 3-position toggle switch and will only take effect
when the vehicle is above a set speed (approximately 25mph to 30mph) and the
torque convertor lock-up clutch is engaged. The lock-up clutch usually engages
when the vehicle is cruising with little throttle action.

On most vehicles, the lock-up clutch can be manually engaged by applying pressure
to the accelerator pedal until lock-up engages, then lift foot off the accelerator.
Accelerator pedal pressure is also required after shifting out of or into overdrive to
reengage the lock-up. The TorqLoc is programmed to disengage the lock-up
clutch once the vehicle’s speed drops below a preset speed.

When the 3-Position toggle switch is in the Down (Green light) position, the
TorqLoc module will keep the convertor lock-up clutch engaged when the exhaust
brake valve is activated (brake switch turned on and accelerator pedal at idle
position). (NOTE: The Down position has no operation if the TorqLoc module is
not wired up to an exhaust brake.) The Middle (White light) position is the
off/neutral position for the TorqLoc module. The Up (Red light) position will
manually keep the convertor lock-up clutch engaged.

For proper operation of the Dodge transmission, the lock-up clutch must be
disengaged before the transmission will shift out of overdrive into 3rd gear. The
TorqLoc module compensates for this by disengaging the lock-up clutch when the
"O/D" button is activated to turn the overdrive off while the exhaust brake is turned
on. To reactivate the lock-up, apply pressure to the accelerator pedal until lock-up
engages, then lift foot off of the accelerator pedal.

Also with Dodge trucks, to prevent excess slippage with the lock-up clutch, the
turbo boost pressure should be equal to or less than 1psi for every 100 engine rpm
(18psi or less at 1800rpm) when engine rpm is below 1800rpm.

On all vehicles, the transmission should be shifted out of overdrive if speed drops
below 40 mph. If not, there could be a transmission shudder as the vehicle speed
decreases until it reaches the set speed that the TorqLoc unit will allow the torque
convertor lock-up clutch to disengage.

With Dodge trucks, the module has an Overdrive inverter option that will disengage
the Overdrive when the truck starts to move after being started up. This will prevent
possible transmission shudder on trucks with raised horsepower and will allow for
the transmission to lock-up the clutch in third gear before reaching overdrive when
starting to up-shift from a dead stop, allowing cooler fluid temperatures when driving
at “city” speeds. This is an option and does not need to be connected for proper
operation of the TorqLoc module, ignore all references to the “Inverter” if this option
is not desired.

Note: The OD inverter is not compatible with 2005 Dodges. A BD Overdrive Cutout
PN 1031350 may be purchased separately to control OD on a 2005 Dodge

22 September 2015 TorqLoc# 1030395

BD Engine Brake Inc.

Plant Address: 33541 MacLure Rd. Abbotsford, BC, Canada V2S 7W2

U.S. Shipping Address: 88-446 Harrison St, Sumas, WA 98295 U.S. Mailing Address: P.O. Box 231, Sumas, WA 98295

Phone: [phone] | Fax: [phone] | Internet: www.bd-power.com

4

Transmission Quirks

Some Dodges built between the production dates of 09/95 to 04/96 have had
computers that the programming for the transmission control has caused some
lock-up control problems and/or will cause the TorqLoc not to operate correctly. If
this occurs, the computer can be "re-flashed" to current specifications at most
Dodge dealerships, labor charges (usually 1/2 hour) may apply.

Some Dodges that are of the 1999-up model years and are of California
specifications may require the Transmission Relay to be reinstalled back into it's
socket, which would have been removed in the "1996-up Dodge "TRANS" Relay
Bypass" section of this manual.

Note that if you have installed the unit on a Ford and you have a higher autoloc
unlock speed in overdrive or drive, you most likely have a coast clutch problem in
the transmission. A BD Pressureloc can help to prevent this.

Other items installed that may effect the operation of the transmission may have an
effect on the operation of the TorqLoc (i.e. auxiliary transmissions). Please make
this known if contacting the BD Technical Service Department.

Compatibility With Other Exhaust Brake Brands

For the Down (Green light) position, where the TorqLoc module will keep the
convertor lock-up clutch engaged when the exhaust brake valve is activated (brake
switch turned on and accelerator pedal at idle position), most of the provided
diagrams, instructions and parts relate to the installation and operation of this unit in
conjunction with any BD Exhaust Brake.

In this manual, we have provided some diagrams and additional instructions for
some of the other systems that we have had access to their diagrams. An
installation in conjunction with any other system should only be done with instruction
from one of our BD Technicians, with wiring diagrams and/or schematics provided
to them. Additional lead-time, parts and/or labor may be required.

For Jacobs E-Brakes installed on Dodge trucks with the 24 valve ISB engines and
all US Gear D-Celerator applications, ignore hooking up the TorqLoc to the brake
wiring, and follow the wiring instructions as if there was no exhaust brake installed.

NOTE - Pac Brake exhaust brakes only: If the truck has a 6BTA 12 valve

engine with 60lb springs, remove the Pac Brake valve and drill out the
pressure relief hole from 9/32” to 31/64”. This step is NOT required for the 24
Valve engines or newer models.

22 September 2015 TorqLoc# 1030395

BD Engine Brake Inc.

Plant Address: 33541 MacLure Rd. Abbotsford, BC, Canada V2S 7W2

U.S. Shipping Address: 88-446 Harrison St, Sumas, WA 98295 U.S. Mailing Address: P.O. Box 231, Sumas, WA 98295

Phone: [phone] | Fax: [phone] | Internet: www.bd-power.com

5

Adjusting For Application

Before installing, open the box up by removing two screws on bottom of module.
On the opposite end of the circuit board from the terminals, there is selection of 8
"dip" switches. These dip-switches control the speed that the TorqLoc module will
disconnect the lock-up clutch. We have provided settings for the module to
disconnect the lock-up at approximately 25mph to 30mph. If you find that the set
speed is too high or low for the vehicle, phone our technical service department for
alternative settings.

NOTE: To ensure proper function of the dip switches, flip each dip switch back and
forth once before setting them, even if the dip switches are already set for the
application it’s being installed on.

The “LED” (Light Emitting Diode) on the circuit board will show a Red light when the

TorqLoc is functioning. Once the unit is installed, test drive the vehicle to make
sure the light comes on and then turns off at the set speed.

Wiring the TORQLOC (with an exhaust brake)

Disconnect the ground (Negative) terminals on all vehicle batteries before starting
installation. The following instructions are divided per wire going up to each
individual terminal labeled on the TorqLoc module, and the terminals in these
instructions will be numbered starting from the top at the +12V terminal. Follow
along with the diagrams following the written instructions for ease of installation.

After wiring, additional instructions will follow for 1996-up Dodges. For 1999-03
Ford PowerStrokes, remove the driver’s side front fender well for access to
computer harness. When possible, check for continuity through all Posi-Tap™
connectors after you have installed them. We suggest soldering and shrink tubing
all connections, but we also provide Posi-Taps™ for your convenience.

22 September 2015 TorqLoc# 1030395

BD Engine Brake Inc.

Plant Address: 33541 MacLure Rd. Abbotsford, BC, Canada V2S 7W2

U.S. Shipping Address: 88-446 Harrison St, Sumas, WA 98295 U.S. Mailing Address: P.O. Box 231, Sumas, WA 98295

Phone: [phone] | Fax: [phone] | Internet: www.bd-power.com

6

+12V

#1

TorqLoc power lead (Red wire)

Using a test light or multi-meter, find a key switched +12 Volt power source in the
wiring harness under the dash. Connect the Red wire to it using a black Posi-Tap™
and connect the other end of the Red wire to the +12v terminal on the module.

GND

#2

TorqLoc ground (Black wire)

Connect to any bolt/screw under the dash that is a good ground.

LOCATION OF DODGE CUMMINS ECM & HARNESSES

VSS

#3

Vehicle Speed Sensor (Green wire)

Locate the VSS (Vehicle Speed Sensor) wire in the vehicles computer wiring
harness (see chart). Run the TorqLoc Green wire to the VSS wire and cut off any
excess, leaving some slack. Connect to the VSS wire using a gray Posi-Tap™, or,
solder the Green wire to the VSS wire and protect it from the elements (i.e. liquid
electrical tape).

DODGE

(5.9L)

2004-2005

Pin 11 at ECM C2 50 pin (Dark Green w/Yellow tracer)

1996-2003

Pin 27 at PCM C2 (White w/Orange Tracer)

1994-1995

Pin 47 on PCM (White w/Orange Tracer)

FORD

(7.3L)

1995-2003

Pin 58 at ECM (Gray w/Black Tracer)

1990-1994

Pin 3 at ECM (Gray w/Black Tracer)

CHEVY

(6.5L)

1994-2000

Pin 15 (Dark Green) at VSS Buffer beside the ECM
(Behind glove box)

1992-1993

Light Blue w/Black Tracer at VSS Buffer by ECM