Hey folks! It's been awhile since I posted. Ran into a problem and need some advice.

A couple years ago I installed a BD Exhaust Brake on my 2005 Dodge 3500, 5.9 Cummins, standard shift. I haul a heavy horse trailer and heavy loads of hay occasionally. The BD exhaust brake has worked very well and I am very pleased. Howsoever...recently my EB engaged and sounded like it was blowing through my heater vent inside the cab. After lifting the hood and engaging the EB to see where the blowby was coming from, I discovered it is blowing through the valve cover, and very loudly! So, evidently, I have a problem in my valve train in connection with my EB. Luckily, the truck still runs well, so maybe it's not fatal.

In looking through a bunch of threads on various forums, I am finding a lot of information recommending 60# valve springs on the gen 1 and 2 engines for EBs, but I'm finding nothing about it for gen 3 24 valve engines. I'm hoping somebody on here has some knowledge about this and can point me in the right direction as to what might have happened (I haven't yet cracked open the top end to look) and what my options are to remedy the situation.

As a side-note, I my turbo has about 355,000 miles on it now, so I am considering replacing it with a larger unit, or possibly a compound turbo setup to get a bit more towing juice, so I can keep up with my buddies in their new Fords :}. That would also involve new head studs and new injectors....thoughts for the future.

Any help is appreciated.

 

I'm researching EBs for my '05 and came across your post, so guessing here. Perhaps your EB pressure regulator is not regulating down to the 65# spec and the EB is over-pressurizing the exhaust manifold and lifting the valves. You'd need a back-pressure gauge installed ahead of the EB to tell. Seems odd though that it would do this at idle with the hood up unless there are problems with the EB electrical controls too that let the EB engage at idle. Again, just a guess after reading through installation manuals from BD and PacBrake.

 

I should have posted that I figured out what the problem was. There is an unused port for a EGT sensor on the elbow back behind the bracketry for the exhaust brake. Apparently, the plug worked its way loose and fell out and every time I engaged the exhaust brake, I was blowing hot exhaust out that port, which is why it felt like the exhaust was coming from the valve cover. it's pretty well hidden and tough to get to. I found it when I replaced the exhaust manifold gaskets, thinking maybe it was an exhaust leak through one of the gaskets! Oh well. Live and learn.

so, now "the rest of the story."

I was towing my horse trailer, heading for the Grand Canyon to ride across the canyon. As I was pulling up Scipio Hill on I-15, just north of Fillmore, Utah, I started hearing an engine knock. I limped into Fillmore and made it to a reputable diesel shop, Stevens Diesel Power. Whether it was a fuel knock or rod knock, I still don't know, but the long and short was that I had blown my second motor. That one had only about 75,000 on it. So, rather than rebuilding that motor again, I ordered a long block and am having the shop add the following options to it:
- ARP head studs
- 62mm turbo (Borg Warner S362SXE)
- stronger valve springs
- 15% over (50hp) injectors
- new heavy-duty clutch
- new water pump
- retaining the BD exhaust brake and BD Pulse exhaust manifold from my old motor
Should be putting put around 550hp.

I will soon add a new lift pump with filters and a new tuner. I am retiring my Bully Dog Power Pup, after blowing my second motor.

So, now I will be able to keep up with my buddies in their new Fords while we haul our horses to our favorite riding destinations!