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6 December 2005 Torq/UnLoc #1030398 1
BD Torq/Un-Loc
Torque Converter Control System
Part# 1030398
ENSURE YOU READ ALL INSTRUCTIONS BEFORE INSTALLING THIS PRODUCT
BD Engine Brake, Inc.
Plant Address: Unit A10, 33733 King Rd, Abbotsford, BC, Canada V2S 7M9
U.S. Shipping Address: 88-446 Harrison St, Sumas, WA 98295 U.S. Mailing Address: P.O. Box 231, Sumas, WA 98295
Phone: 604-853-6096 Fax: 604-853-8749 Internet: www.bd-power.com
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6 December 2005 Torq/UnLoc #1030398 2 TABLE OF CONTENTS Welcome ........................................................................................................................ 3 The BD Torq/UnLoc Advantage ..................................................................................... 3 Operating The BD Torq/UnLoc....................................................................................... 3 Transmission Quirks......................................
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6 December 2005 Torq/UnLoc #1030398 3 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”.
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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).
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6 December 2005 Torq/UnLoc #1030398 5 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
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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
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6 December 2005 Torq/UnLoc #1030398 7 Wiring – With Exhaust Brake Installed Disconnect the ground (negative) terminals on all vehicle batteries before starting installation. The following instructions will be divided up for wiring up each individual terminal labeled on the Torq/UnLoc module. These terminals in these instructions will be numbered starting from the top at the +12V terminal. Follow along with the diagrams after the written instructions for ease of installati
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6 December 2005 Torq/UnLoc #1030398 8 BPS #4 Brake Power Signal (Brown Wire) The module is looking for the 12-volt positive signal that triggers the exhaust brake to activate. Connect the Brown “Y” wire to BPS terminal on the module and connect the Brown wire from the toggle switch to one of the open ends of the “Y” wire. Connect one end of the supplied section of Brown wire to the other open end of the “Y” wire. Brake System Connection Posi-Tap™ onto the wire leading
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6 December 2005 Torq/UnLoc #1030398 9 PCM & TCC #6-7 Converter Control (Yellow #6 and Blue #7 wire)) Locate the vehicle’s Torque Convertor Control (TCC) as described in the following chart. Cut the applicable wire and attach one side of a blue Posi-Lock connector to the wire leading back to the transmission, and, attach one side of another blue Posi- Lock connector to the wire heading to the vehicles computer (ECM or PCM). Connect the Torq/Unloc yellow wire to the PCM (#6)
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6 December 2005 Torq/UnLoc #1030398 10 For 1999-2002 Dodges, if the overdrive inverter option is desired, flip Dip Switch #8 to the “UP” position, no matter what gear ratio you set the other switches to. BRAKE #9 N/A This connection is not used in the Torq/UnLoc kit. Testing with an Exhaust Brake With the module pulled out enough to be easily visible while driving, take the vehicle for a drive. Turn the toggle switch to the Up (Red Light) position and first chec
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6 December 2005 Torq/UnLoc #1030398 11 If this fails to occur, check the O/D wire color and connection to that wire and that the wire is on the right terminal at the module. If any of the functions still fail to occur, phone our technical service department for further assistance. To bypass the effects the module (if required), unplug the blue and yellow wires of the transmission wire and plug the transmission wires back together. After final wiring and testing has bee
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6 December 2005 Torq/UnLoc #1030398 12 1996-2002 Dodge "TRANS" Relay Bypass Remove the cover on the Power Distribution Center (PDC) box, behind the driver's side battery. Replace the "TRANS" relay (see diagrams below, or bottom of PDC cover) with the copper jumper provided. This IS NOT required on 1999-2002 California Spec. model trucks. If the Engine Service Light comes on after operation, try reinstalling the relay then clear the fault code from ECM. BD Engine Brak
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6 December 2005 Torq/UnLoc #1030398 13 Wiring Diagrams Torq/UnLoc (Dodge Trucks) BD Engine Brake, Inc. Plant Address: Unit A10, 33733 King Rd, Abbotsford, BC, Canada V2S 7M9 U.S. Shipping Address: 88-446 Harrison St, Sumas, WA 98295 U.S. Mailing Address: P.O. Box 231, Sumas, WA 98295 Phone: 604-853-6096 Fax: 604-853-8749 Internet: www.bd-power.com
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6 December 2005 Torq/UnLoc #1030398 14 Brake Connection Diagrams BD Brake (12V Dodge & Chevy 6.5L) / PacBrake (Dodge) BD Brake (1998-2002 24V Dodge) BD Engine Brake, Inc. Plant Address: Unit A10, 33733 King Rd, Abbotsford, BC, Canada V2S 7M9 U.S. Shipping Address: 88-446 Harrison St, Sumas, WA 98295 U.S. Mailing Address: P.O. Box 231, Sumas, WA 98295 Phone: 604-853-6096 Fax: 604-853-8749 Internet: www.bd-power.com
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6 December 2005 Torq/UnLoc #1030398 15 Jacob’s E-Brake (6BTA) The Torq/Unloc Basics The basic difference between the TorqLoc (Up/Red-light) and AutoLoc (Middle/White- light) functions is that the AutoLoc automatically controls the TCC lock up signal once it receives a power signal from the exhaust brake switch, and, the TorqLoc is for manual lock-up of the clutch. So in comparing between the AutoLoc and the TorqLoc, the TorqLoc will force the converter clutch to loc
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6 December 2005 Torq/UnLoc #1030398 16 When downshifting with Dodge trucks, you have to apply throttle pressure until the factory computer says everything is okay and locks up the torque converter clutch. As soon as this happens, you should remove throttle pressure and the AutoLoc will keep the torque converter clutch applied until you get down to about the 25mph mark. The set speed is adjustable and one can set it for a higher mph so you don’t have to worry about remembering
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6 December 2005 Torq/UnLoc #1030398 17 BD ENGINE BRAKE DISCLAIMER OF LIABILITY Other than as expressly set forth herein, BD ENGINE BRAKE, Inc. (hereafter collectively, "SELLER"), together with its distributors, jobbers and dealers shall in no way be responsible for the PRODUCT’S proper use and service. In no event shall SELLER be liable for any special, incidental, indirect or consequential damages of any kind or nature, whether or not BUYER was advised of the possibility o
