C11642 DODGE PRESSURE SWITCH KIT
FOR 2003-2007 DODGE KITS THAT WERE SUPPLIED WITH AN AIR TANK
INSTALLATION
- DODGE
PRESSURE
SWITCH
KIT, L6094
INSTALLATIONMANUAL
MANUAL
- INSERT
TITLE HERE,
L1234
KIT CONTENTS
C11640
C11641 M8028 C11816 Pressure Switch Harness Blue Butt Connectors Tie Straps REQUIRED TOOLS
(1)
(1)
(3)
(6)
•
•
•
•
•
•
/16", 1/2", 9/16" open end or box wrenches
Adjustable Wrench
Pipe Thread Sealant
Spray Bottle with Dish Soap/Water
Wire stripers
Wire crimpers
7
Thank you and congratulations on the purchase of a Pacbrake kit. Please read the entire installation manual
prior to starting the installation to ensure you can complete the installation once started.
BEFORE STARTING:
Ensure the application information is correct for the make, model and year of the vehicle you are installing it on.
This kit is designed to prolong the life of the pressure switch for your air system.
Installation
1
Locate the pressure switch of the Pacbrake air system, it will be green with two blue wires molded in to the end. Original kits have the pressure switch located in the top of the air tank. Newer kits will have the pressure switch located on the compressor assembly.
The wiring modification is the same for both locations.
The two locations are shown in photos.
2
Disconnect the weather-pac connector of the Pacbrake harness
to the pressure switch.
PG
PG11
INSTALLATION
- DODGE
PRESSURE
SWITCH
KIT, L6094
INSTALLATIONMANUAL
MANUAL
- INSERT
TITLE HERE,
L1234
3
At the harness end of the weather-pac connector, pull back the
wire loom. There will be two red wires. Cut both wires close to the
connector and discard the connector end.
Strip ¼" off both wires of the harness. Attach the two wires
together using the heat shrink butt connector supplied.
Heat this connection to provide a water tight seal.
4
For pressure switches located at the compressor, it is necessary
to have the pressure switch fitting end pointing on a slight downward angle so moisture cannot accumulate within it. Some early
kits had the pressure switch facing up. These will need to have
the fittings removed and repositioned. Make sure to use thread
sealant on all fittings upon re-assembly.
See examples: photo A is the correct positioning of the switch
and photo B is incorrect.
Install the new pressure switch provided.
A
B
PG
PG22
INSTALLATION
- DODGE
PRESSURE
SWITCH
KIT, L6094
INSTALLATIONMANUAL
MANUAL
- INSERT
TITLE HERE,
L1234
6
Connect the weather-pac connector of the new supplied harness to the new pressure switch. Route the other end of the harness
to the drivers side battery and locate the black 16 awg. (ground) wire of the existing pacbrake harness. Cut this wire approximately 2" from the negative post of the battery. Strip ¼" off each end and crimp on the remaining two butt connectors. Shorten the new harness to the correct length if needed. Strip ¼" off each wire and crimp onto the butt connectors.
Once crimped, heat the connectors to provide a moisture
tight seal.
7
Secure all wiring away from heat sources and moving parts with the tie straps provided. Test the system for operation and air
leaks. Air leaks will shorten the compressor life.
PG
PG33
L6094 08.19.10
INSTALLATION
- DODGE
PRESSURE
SWITCH
KIT, L6094
INSTALLATIONMANUAL
MANUAL
- INSERT
TITLE HERE,
L1234
BEFORE
Manual
Transmission Only
Pacbrake
On/Off
Switch
Red
White
Optional
Clutch Switch
C18042- Manual
Transmission Only
Pressure
Switch
Black
Black
Pacbrake Air Tank
Optional
Shifter Mounted
ON/OFF Switch
White
Pacbrake
Solenoid
Connect to Pin #39
White to Pin 39
Black to Ground
Air Intake Connect to filter
View shown is of harness
connector installed in ECM
Blue
10
20
30
40
11
21
31
Red
CUT HERE
46
Solenoid
Relay
87
50
Black
85
86
Compressor
Relay
87
86
30
10 Amp
Fuse
30
Driver’s Side Battery
30 Amp
Fuse
Red
+
Pos.
85
Red with White Trace
Ignition
Power
Source
Black
45
Connect to Pin #42
Red
CUT
HERE
Red
1
41
connector
connector
50 Pin Connector "B"
Optional
Compressor
On/Off Switch
CUT HERE
Neg.
-
*Not provided in this kit
REV8.WIRING
AFTER
Manual
Transmission Only
Pacbrake
On/Off
Switch
Red
White
Optional
Clutch Switch
C18042- Manual
Transmission Only
Black
Pacbrake Air Tank
Optional
Shifter Mounted
ON/OFF Switch
White
Pacbrake
Solenoid
View shown is of harness
connector installed in ECM
10
20
30
40
45
46
10 Amp
Fuse
Solenoid
Relay
87
50
Connect to Pin #42
Red
Red
Butt Connector
Black
85
86
Compressor
Relay
87
86
30
30
Red
30 Amp
Fuse
Driver’s Side Battery
+
Pos.
85
Red with White Trace
Optional
Compressor
On/Off Switch
Black
11
21
31
41
Blue
Red
1
connector
connector
50 Pin Connector "B"
Neg.
-
*Not provided in this kit
Black
Black to Ground
Air Intake Connect to filter
Connect to Pin #39
White to Pin 39
Ignition
Power
Source
Pressure
Switch
Black
Black
Butt Connector
Blue
Butt Connector
Blue
C11642 RETRO FIT WIRING
PG
PG44