04 ISX weak jake brake

Discussion in 'Volvo Forum' started by Slow302, Jan 24, 2014.

  1. Slow302

    Slow302 Medium Load Member

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    I just got inframe overhaul done by small shop in IN at 1.4k miles because exhaust gases got into coolant, looks like cracked head since head gasket was still good. Before that jake brake worked fine in all 3 positions. Now 1st and 2nd are still same as before but 3rd position or highest one is kinda weak. Looks like its weakest in top gear which is mine 13th gear. When i hit jake brake it start like 1st position than gets little better but not like before. If i hit it in 12th or lower gears its much stronger but not like before. Mechanic who did overhaul tried swap some kinda jake brake plates that sitts inside head under tho selenoids but still nothing. He said tune up my help when i get back to his shop in 30k miles for readjusting valves but i thing something else is bad
    Inframe included full kit, head, injector cups,,connecting rods, EGR cooler, Oil cooler, oil pump,air compressor.
    Turbo have about 550k miles on remain one and still runs great 35-40 psi. EGR valve have about 100k miles
    There is no codes for jake brake.
    So what do you guys think may be
     
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  3. passingthru69

    passingthru69 Road Train Member

    Have him rebuild the jakes. Like he said tune up kit. Why they did not do that when your overhauled it has me worried..
    They had to pull them off for overhaul
     
    KB3MMX Thanks this.
  4. UltraZero

    UltraZero Medium Load Member

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    last year, I had something similar. I have a 6 way jake brake setup. 1 nothing to super lite. 2 - 6 progressively more powerful. Well, I didn't have much after 2 last year. I had a valve job done and they are stronger then they were when I bought the truck.

    Maybe a re-adjustment is needed.
     
    Last edited: Feb 17, 2014
  5. Slow302

    Slow302 Medium Load Member

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    Well it was time for tuneup after overhaul. I also bought 2 new engine brake selenoid and wiring harness. Same thing 1st and 2nd engine brake working fine but 3rd one is still weak. And same as before looks like its cutting off on low rpms 1200 od less. Its not straight woshhhhhh. Sound like one of those guys with 10" stacks and wosh wosh wosh just not as loud as 10" stacks. When i was picking up selenoids i talked with cummins service guy and be is saying my turbo isnt working with jake brake because its air operated accuator. If i have one that is electronic than will work together with jake brake. So he is saying if turbo works fine under hard pull with full boost than its not turbo.
    How about switch. Or meybe broken jake braks wire outsixe of head, where thkse two wifes goes to. ECU ?
     
  6. UltraZero

    UltraZero Medium Load Member

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    Well, I took my truck in last year for an overhead. I had prior a wiring harness issue for the jakes. Once the overhead was done, Now, I can go down a pretty steep hill and kick the jakes on and I have been using between settings 2 and 4. Setting 6 basically is crazy strong. If I'm going down hill, at 55, it will bring me down to 40 pretty fast. Adjustment to jakes might be the problem.

    although, you did write 1 and 2 work. Hmmm..
     
  7. Slow302

    Slow302 Medium Load Member

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    Well jake is still the same kinda week on 3 but it may be just fine. What else i found is that when i first use isnt like fusssss. More like fus ssss sssss. Looks like longer i use it it opens up with full noise witbout split second cutting. I think VGT is going bad
     
  8. LowTowBoy

    LowTowBoy Bobtail Member

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    I have a first gen 565 ISX that I solved the enging brake issue on myself, after several attempts and $$$ at my favorite shop that kept missing it.

    In order to have an optimal operating engine brake, all the components that are in it need to be in good condition. On a rebuild such as yours, I'm kind of surprised they didn't at least give you the option to tune the engine brake up by replacing critical worn parts, such as rocker shaft and/or rockers themselves, and oil slave pistons in the rockers at least. I had same problem, paid $$$ and still had it, so I took the valve cover off (I've been doing this stuff 30+ years, so it's not for just anyone to try at home,) checked each individual solenoid, and upon activating #3, I found a faulty oil slave piston in one rocker. I replaced all 6 of them ($180.00) and it's back to normal.

    Not saying this will solve your particular issue, but the point being is that while doing an inframe, the integrated brake system should at least be tuned up while inside the cover, to ensure proper operation. There's things that wear and will cause a loss of oil flow/pressure to components that make the engine brake perform to full capacity. Rocker shaft, rockers have detent holes in them that wear....oil slave pistons go bad like mine did...several key factors that will reduce the performance of the braking power if not addressed.
     
  9. Slow302

    Slow302 Medium Load Member

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    Well i decided to replace turbo since it started to whine and engine brake got weaker even more. My factory turbo was replaced at 750k due to sticking nozzles but didnt go boom. Reman replacement lasted 780k. This time nozzles started to stick just little bed and shroud plate in turbine housing was cracked.
    Engine brake is about 50% stronger, full boost is little higher and pull harder. Not bad for $2500 repair (no labor, i replace by my self)
     
  10. Slow302

    Slow302 Medium Load Member

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    Im still having issues with weak jake brake. Does anyone know where 3 wires from pass throught connector coming from? ECU maybe ? If so what are pins on ECU plug. I wanna check those wires to see if they have good resistance
     
    Last edited: Mar 8, 2016
  11. Slow302

    Slow302 Medium Load Member

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    I forget to mention this time switch position #2 and #3 have same performance as #1. Since my original post i replace turbo 2 times, both solenoids, jake brake harness, egr 2 times, 3 times overhead adjustment, 3 front jake brake rockers. Now #2 and #3 is same as #1
     
    Last edited: Mar 8, 2016
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