Banks Brake

Test Setup

A 2006 Dodge Cummins pickup was equipped with the Banks DynaFact® data acquisition system to measure vehicle speed, engine RPM, exhaust backpressure, transmission line pressure and braking horsepower.

Test runs on a 7% grade in the vicinity of Southern California's daunting Cajon Pass were done with the gear selector in both Drive and 2nd. Tow/Haul mode was used in all cases, per Dodge’s recommendations. 55 mph was established at the top of the hill, and the foot brake was applied only if it became necessary to keep the vehicle at a safe speed (no greater than 65 mph). Multiple configurations were tested: stock, Banks Brake with Computerized Brake Controller and SmartLock® (CBC), PacBrake, Jacobs and BD.

All of the brakes tested were a direct mount configuration. Each of the competitive brakes was controlled by the vehicle ECM (an option that became available starting in the 2006 model year). In addition to road testing, flow bench testing was conducted on each of the brake assemblies.

Test Results

Stock

• Excessive use of foot brake required during descents in Drive: indication of possible runaway condition
• Heavy use of foot brake required in 2nd gear to prevent excessive redlining & consequent engine damage

Banks Brake with CBC and SmartLock ®

• Smooth, controlled downhill descents
• The only exhaust brake that didn’t require use of the foot brake in Drive
• Highest peak braking horsepower
• Immediate response
• Superior airflow with brake open
• By far, the quickest braking response time
• Transmission line pressure around 133 psi during descent
  • This added line pressure keeps transmission clutches firmly applied
  • Protects the transmission
  • Over 50% more protective line pressure than the others provide
• Vacuum pump produces no audible noise over normal engine sound

BD Brake

• Uses a noisy electric pressure pump
• Insufficient braking power: had to use foot brake during descents in Drive
• Slow reaction time
• Weakest of all exhaust brakes tested
• Doesn’t operate in 1st gear
• More restrictive when open; hurts performance
• Automatic-equipped trucks prior to ’06 require BD’s programmable Tow Loc and Pressure Loc kits to electronically control torque converter clutch engagement
• Transmission line pressure just 83 psi during descent

Jacobs Brake

• Insufficient braking power: had to use foot brake during descents in Drive
• Doesn’t operate in 1st gear
• More restrictive when open; hurts performance
• Transmission line pressure just 82 psi during descent
• Slow reaction time

PacBrake

• On/Off brake activity while in cruise condition results in noisy release of air pressure
• Insufficient braking power: had to use foot brake during descents in Drive
• Slow reaction time
• Doesn’t operate in 1st gear
• Most restrictive of all brakes when open; hurts performance
• Exhaust pressure regulation requires multiple moving parts that could stick or fail
• Transmission line pressure just 83 psi during descent

Banks Brake versus the competition

	BANKS	BD	PACBRAKE	JACOBS	COMMENTS
Brake Delay	1	4	2	3	1=Best, 4=Worst See Instant Braking Power chart
Braking Power	1	4	2	3	1=Best, 4=Worst See Superior Stopping Power chart
Open Flow	1	3	4	2	1=Best, 4=Worst See Unrivaled Flow chart
Overdrive Cancel in Tow/Haul Mode					Increases RPM for better braking
Brakes in all Gears & Locks Torque Converter					Added safety when low speed must be maintained while descending steep grades
Free from Wire Tapping or Splicing					Far easier to install, Banks Brake needs no modifications to stock wiring
Maintenance Free					Calibrated at the factory, Banks Brake never needs adjustment or maintenance
Boosts Trans Line Pressure					Protects the transmission under higher braking loads
High-Temp Sealed Bearing System					Added durability & reliability; zero maintenance
Lowest Operating Speed (as tested on an '06 vehicle)	14 mph	24 mph	24 mph	24 mph	Only Banks Brake provides critical control at lower speeds

Includes:
Cast, large-bore brake housing assembly; High-force 4-1/4" vacuum actuator; Belt-driven vacuum pump with serpentine belt for quiet operation; Large butterfly valve with super-alloy shaft-and-bearing system; Wire loom; Mounting hardware.

TECH ARTICLE: How an Exhaust Brake Works

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