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Old 06-22-2015, 09:00 PM   #1
3 Rivet Member
2002 25' Classic
Kalama , Washington
Join Date: Feb 2003
Posts: 163
Cummins Exhaust Brake Troubles

Our '01 Dodge 6spd stick is intermittently cutting out or not engaging at all. It always resumes operation after shut down/cooldown. Have had a handful of throttle sensor fault codes during the same time frame (sensor replaced, but additional faults since). Anyone had the same experience and found a Rx? It's irritating since we can't depend on the downhill braking when towing.
Each time it's been in for repair (at Dodge, Cummins and separate mechanic), the report is "We can't duplicate the problem you describe". Thanks for any help you can offer.
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Old 06-23-2015, 07:54 AM   #2
Vintage Kin
Fort Worth , Texas
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Search at Cummins Forum in generation subforum on drivetrain
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Old 06-23-2015, 10:47 AM   #3
3 Rivet Member
2002 25' Classic
Kalama , Washington
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thnx… will do!
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Old 06-23-2015, 11:10 AM   #4
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2005 28' Safari
Mono City , California
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Posts: 66
Here is some info on operation of the exhaust brake from Cummins Quickserve. As you can see the throttle position sensor is an input to the ECM, and control of the exhaust brake.

Can you get me the engine serial number and some of the codes you have experienced with the throttle position sensor. I can then check Cummins service information to see what maybe the cause.

The exhaust brake retards engine speed by creating high exhaust back pressure. This back pressure is obtained by restricting airflow through the exhaust system. The exhaust brake can only be activated when the accelerator pedal is at its low idle position. With the throttle at low idle position, fueling commands to the cylinders will not detract from the braking power of the brake system.

The exhaust brake is actuated by a solenoid. The solenoid can be controlled by the engine's electronic control module (ECM). The ECM monitors its sensors (such as accelerator pedal position and engine speed) and energizes the brake solenoid when the proper braking conditions are present.
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Old 06-25-2015, 04:12 PM   #5
3 Rivet Member
2002 25' Classic
Kalama , Washington
Join Date: Feb 2003
Posts: 163
Great help, TB, and thank you. I've learned a little more about my brake in the meanwhile. It is a PAC Brake. Local Cummins shop referred me to them for tech support. I was sent service and maintenance bulletins which I shared with my mechanic.
I can not provide a VIN because my truck is in the shop. The codes I remember seeing were for Throttle Sensor and Companion Module (which Dodge says is redundant and does not specifically indicate anything).
I'm hopeful that some PAC Brake Rx is now possible. Should know tomorrow and will share as there is news. Thnx again.
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