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Old 09-07-2019, 03:06 PM   #1
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Alpine Owners Club
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2004 Jake Brake problems

This is a 2004 ISL 400, it has a 2 stage Jake Brake, not a Pac brake or exhaust brake. There are 2 solenoids inside the valve cover that activate it. On low it only uses 3 cylinders for braking, on high it uses all 6 cylinders.

When I first got this coach, the Jake did not work at all - found that out on Red Mountain Pass. After that adventure, I dug around and found the plug for the rear solenoid behind the AC compressor was not plugged in. I plugged it in and now have 1/2 brake power - or the equivalent of low. No matter if the switch is on high or low - same brake power.

I decided to try and find the other one - near the transmission end of the motor. I found it and that connector is plugged in. I got a long screwdriver on it and moved it around to be sure it is making contact - seemed to make no difference. It's the small right angle connector plugged into the side of the head.




I followed the wiring down to an area above the starter and found a couple of plugs that look suspect. They are both 2 wire and look like they might connect together, but they are zip tied off so they can't reach. I would have to cut the ties off and try them. It's very hard to get to this area - I had trouble getting a picture. The female appears to be at about top left in the picture, male is at center right.





I think the male may be coming from the Jake brake wiring, but I'm not sure.

It has a jumper crammed in it - see below.




Is anyone familiar with the wiring in this area?
I may be able to get in there to try putting those together but I have a couple of concerns:
1. I'm probably going to hurt myself getting in there. I took there pictures from the air cleaner looking over the frame.
2. If those don't belong together, I could cause some trouble.


I have adapted to driving with a weak Jake - but would sure like to have the full effect.

Thanks, Tim
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2004 Alpine Coach, 400 Cummins ISL, 40'
Weatherford Texas
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Old 09-07-2019, 03:18 PM   #2
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Take the pictures to your Cummins engine service center.
Or email them.
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Old 09-08-2019, 08:42 AM   #3
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Pretty sure wiring for both High and Low engine brake activation goes thru a two wire connector from the ECM wire loom. If your two wire connector was disconnected you wouldn't get any engine braking, High or Low. iiwm I would not connect any unknown circuits together to test them. One side of the two wire activation circuit has an additional connector with a jumper plug like your photo.
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Old 09-08-2019, 09:24 PM   #4
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Jake wire

Under the valve cover there is a wire to the actuator solenoid. It may have been sheared by one of the rocker arms. A few years back I had the same issue
Cummins gets about 40 dollars for the 10 in piece of wire. It has a right angle connector on one end and a spade connector on the other.
If you take off valve cover be careful of the silcone valve cover gasket. If I remember its about 150.00
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Old 09-09-2019, 03:54 PM   #5
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I cannot imagine how fun that valve cover is to remove.
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Weatherford Texas
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Old 09-09-2019, 09:22 PM   #6
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On my 36 it is fairly easy as the bed lifts up for access
Just remove cold air tube and you have access to valve cover
If you have side to side bed I believe there is a floor access, but has many screws to remove and much less room to work
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