BD Diesel Performance 1030398 User Manual

6 December 2005 Torq/UnLoc #1030398

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BD Torq/Un-Loc

Torque Converter Control System

Part# 1030398

ENSURE YOU READ ALL INSTRUCTIONS BEFORE INSTALLING THIS PRODUCT

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

Plant Address: Unit A10, 33733 King Rd, Abbotsford, BC, Canada V2S 7M9

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

BD Engine Brake, Inc.

6 December 2005 Torq/UnLoc #1030398

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TABLE OF CONTENTS

Welcome ........................................................................................................................3

The BD Torq/UnLoc Advantage.....................................................................................3

Operating The BD Torq/UnLoc.......................................................................................3

Transmission Quirks.......................................................................................................5

Compatibility With Other Exhaust Brakes ......................................................................5

Adjusting For Application................................................................................................6

Wiring – With Exhaust Brake Installed...........................................................................7

Testing with an Exhaust Brake.....................................................................................10

Wiring –Without Exhaust Brake....................................................................................11

1996-2002 Dodge "TRANS" Relay Bypass..................................................................12

Wiring Diagrams...........................................................................................................13

Torq/UnLoc (Dodge Trucks).....................................................................................13

Brake Connection Diagrams.....................................................................................14

BD Brake (12V Dodge & Chevy 6.5L) / PacBrake (Dodge) ..................................14

BD Brake (1998-2002 24V Dodge).......................................................................14

Jacob’s E-Brake (6BTA)........................................................................................15

The Torq/Unloc Basics.................................................................................................15

Questions?...................................................................................................................16

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

Plant Address: Unit A10, 33733 King Rd, Abbotsford, BC, Canada V2S 7M9

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

BD Engine Brake, Inc.

6 December 2005 Torq/UnLoc #1030398

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Welcome

Thank you for purchasing the BD Torq/UnLoc Kit. This manual is to assist 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 E-Brake system for the Dodge ISB 24 valve
application and all US Gear D-Celerators, the brake cannot be hooked up to the
module. Follow the instructions that are for “Without Exhaust Brake”.

The BD Torq/UnLoc Advantage

Currently, exhaust brake usage can cause high temperatures in the automatic
transmission due to torque converter slippage, and, only 10% to 80% of the retarding
force is transferred through the fluid coupling of most torque converters.

The BD Torq/UnLoc commands the lock-up clutch of the torque converter to stay
engaged when the BD Exhaust Brake is activated. This allows for up to 100% of the
retarding force to be transferred in 3rd and 4th gear and the transmission oil
temperature to remain low because of little to no slippage occurring when the converter
is in these selected gears.

The BD Torq/UnLoc is also able to prevent the ECM from activating the lock-up clutch
when such an action would drag the engine rpm out of the optimum torque range, or,
when traveling at such speeds that would cause the ECM to cycle the lock-up clutch in
and out.

Operating The BD Torq/UnLoc

The Torq/UnLoc works off of a lighted 3-position toggle switch that will only take effect
when the vehicle is above a set speed (approximately 25mph to 30mph) and the
torque converter lock-up clutch is engaged. The lock-up clutch usually engages when
the vehicle is cruising with little throttle action. (The manual unlocking of the clutch
can be activated at any time.)

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

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

Plant Address: Unit A10, 33733 King Rd, Abbotsford, BC, Canada V2S 7M9

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

BD Engine Brake, Inc.

6 December 2005 Torq/UnLoc #1030398

4

When the 3-Position toggle switch is in the Up (Red Light) position, it will manually
keep the converter lock-up clutch engaged. This is referred to the TorqLoc mode.

The Middle (White Light) position is the off/neutral position and if a compatible
exhaust brake is hooked up to the system, the module will keep the lock-up engaged
when the exhaust brake valve is activated (brake switch turned on and accelerator
pedal at idle position). This is referred to the Stock/AutoLoc mode.

In the Down (Green Light) position, the converter lock-up clutch will be prevented
from locking up. This is referred to the UnLoc mode.

For proper operation of the Dodge transmission, the lock-up clutch must be

rd

disengaged before the transmission will shift out of overdrive and into 3

gear.

The Torq/UnLoc module compensates for this by disengaging the lock-up clutch when
the O/D OFF (Overdrive Off) button is activated to turn the overdrive off while in the
TorqLoc or Stock/AutoLoc modes. To reactivate the lock-up, apply pressure to the
accelerator pedal until lock-up engages, then lift your foot off of the accelerator pedal.

In addition, 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
(example: 18psi or less at 1800rpm) when the engine rpm is below 1800rpm.

The transmission should be shifted out of overdrive if speed drops below 40 mph. If
not, there could be transmission shudder as the vehicle’s speed decreases until it
reaches the set speed that the Torq/UnLoc unit will disengage lock-up.

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 converter 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
Torq/UnLoc module. (Ignore all references to the “Inverter” if this option is not
desired)

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

Plant Address: Unit A10, 33733 King Rd, Abbotsford, BC, Canada V2S 7M9

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

BD Engine Brake, Inc.

6 December 2005 Torq/UnLoc #1030398

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Transmission Quirks

Some Dodge trucks built between the production dates of 09/95 to 04/96 have had
ECM programming for transmission control that has caused some lock-up control
problems and/or will cause the Torq/UnLoc not to operate correctly. If this occurs, the
computer can be "re-flashed" to current specs at most Dodge dealerships. Labor
charges of approximately 30 minutes may apply.

Some Dodge trucks that are 1999-2002 model years and are of California
specifications may require the transmission relay to be re-installed back into its socket.
This relay would have been removed in the "1996-2002 Dodge ‘TRANS’ Relay Bypass"
section of this manual.

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

Compatibility With Other Exhaust Brakes

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 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 Torq/UnLoc to the brake
wiring and follow the wiring instructions as if there was no exhaust brake installed.

NOTE for PacBrake exhaust brakes only: If the truck has a 24 Valve engine or is a
6BTA engine with 60 lb springs, remove the PacBrake valve and drill out the pressure
relief hole from 9/23” to 31/64”. This step is NOT required for the 24 valve engines or
newer models.

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

Plant Address: Unit A10, 33733 King Rd, Abbotsford, BC, Canada V2S 7M9

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

BD Engine Brake, Inc.

6 December 2005 Torq/UnLoc #1030398

6

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
dipswitches.

These dipswitches control the speed that the Torq/UnLoc 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 that it’s being installed on.

The “LED” (Light Emitting Diode) on the circuit board will show a Red light when the
vehicle has surpassed the set speed and the toggle switch is in the Up/Red-light
position, or, when the exhaust brake is activated and the toggle switch is in the
Middle/White-light position. Once the unit is installed, test drive the vehicle to make
sure the light comes on at the set speed.

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

Plant Address: Unit A10, 33733 King Rd, Abbotsford, BC, Canada V2S 7M9

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

BD Engine Brake, Inc.