Diesel Exhaust Brake
- Take the Terror Out of Downhill Towing
- Add Thousands of Miles to Your
- Extend Engine Life With Rapid Cold
- Patented Waste-Gate Design Gives
Powerful Braking at Lower RPMs
Application Chart &
Proudly Made in the U.S.A.
An exhaust brake... is required for Dodge
3500 Pickup and chassis cab models pulling a trailer weight of
10,000 pounds or more."
the Dodge 2001 Towing Guide
(published by Dodge)
Does this sound familiar?
A driver towing a heavy load or driving a big motorhome has
finally made it he has crested the top of that mountain grade and its all
downhill from here. He peers down the highway in front of him running down the side of the
mountain and realizes he has a new set of challenges.
He has a four mile, seven percent grade to navigate with
tons of metal riding behind him and all he has are a set of overworked vehicle brakes to
slow his growing momentum as he starts to gain downhill speed without so much as a tap on
He looks to his right over the edge of the guardrail and
cant see the bottom! Returning his gaze to the road in front of him he sees,
becoming clearer every moment, a line of vehicles at a stop sign at the bottom of the
hill. And all of a sudden there are butterflies coming to life in his stomach and they are
beating their wings furiously.
The driver realizes he is in a "free fall" with
no speed retarding assistance from his engine, so he begins to pump the brake pedal. While
he feels some temporary assistance, and a little security from knowing he is no longer
rocketing down the side of a mountain, he notices that the blood is leaving his knuckles
as he grips the steering wheel. He downshifts and his RPMs begin to soar, but his speed
continues to increase. So as the skin covering the back of his hands becomes almost
transparent, he decides to take the next step the final option.
He stands on the brake pedal with such force that he lifts
himself out of the drivers seat far enough to slip a two by four between him and the
upholstery. Finally, his momentum begins to slow a little. Now his sense of smell
kicks in and as he sniffs the air, he smells something. What is that? Can a person smell
heat? It sure seems like something is burning and he recognizes the pungent odor of
As his brakes begin to roast, they also begin to fade and
lose braking effectiveness. The driver realizes that he is driving on a wing and a prayer,
and he hopes for the best as his lively descent down the mountain grade continues
Why do these problems occur?
A new diesel owner, especially one who is unfamiliar with the
difference between how a diesel engine works compared to the gasoline engine he is used
to, may be unprepared for the braking challenges presented by his new fuel-efficient,
At its very center, the problem arises from the way the
engine runs when there is no pressure on the throttle. When a gasoline engine is idling,
the throttle body butterfly rests in a closed state. The butterfly cuts off air flow so
the engine generates vacuum as the pistons are continually trying to draw air into the
cylinders. This vacuum has a retarding effect on engine output and automatically
provides some braking assistance on downhill grades when the drivers foot is not on
This butterfly-generated vacuum assistance does not exist
in a diesel engine. Even when there is no throttle pressure, the diesel continues to pump
air into the engine.
Is there a solution to fix this problem?
Yes! For decades, big rig drivers have used engine brakes and
exhaust brakes to restrain the engines in their heavyweight diesel tractors. Since engine
brakes create so much noise, they have been outlawed in several mountain communities, and
even at entrances to toll booths on level-terrain highways. The use of engine brakes has
been severely curtailed. So even though they are effective, they are annoying and
On the other hand, exhaust brakes are relatively quiet.
They build the back pressure required to retard the vehicles momentum without
producing all the clatter.
In the early 1990s this "big rig" technology
became available to pickup and motorhome owners.
How does an exhaust brake do what it does?
In effect, an exhaust brakes turns the diesel engine into a
big compressor. In contrast to the gasoline engine which restricts air intake, the exhaust
brake restricts exhaust outflow to create pressure. And with diesel engines creating 200+
horsepower, regulating back pressure can provide powerful braking assistance for the
On most downhill grades exhaust brakes engage automatically
to help slow the vehicles momentum. This permits the diesel-powered pickup or
motorhome to stop quicker. Exhaust brakes also save wear and tear on the wheel brakes.
Finally, and most importantly, safety is increased and the butterflies in the
drivers stomach go back to sleep and the driver is truly in control of his rig.
U.S. Gear offers exhaust brake alternativesCutting off air to a gasoline engine is not a problem.
They are designed to operate with a throttle body. Like human beings, though, if diesels
dont get air, they die. Butterfly valves, however, are the most effective way of
blocking flow in the vehicles systems. Thats why butterflies are used in
exhaust brakes "behind" the engine for diesels.
U.S. Gear offers two types of exhaust brakes both
utilize butterfly valves to create back pressure.
The "Standard" Model
Like all other exhaust brakes, the "Standard" model
D-Celerator controls pressure using orifices (holes) in the butterfly. The orifice is
sized at the factory to keep your engine from over-pressuring at extreme RPMs.
As you can see from the graph,
the orifice (hole) regulated "Standard" model builds maximum pressure at higher
If you drive a small pickup or motorhome, and you rarely
visit mountain communities, then the "Standard" is the perfect solution to help
your vehicle perform up to its braking potential.
The "Super Duty" D-Celerator
U.S. Gears "Super Duty" model also uses a
butterfly to create back pressure. But unlike other exhaust brakes, the "Super
Duty" D-Celerator has a patented turbo-inspired waste gate
to manipulate the amount of pressure built up in the engine. This means that when the
butterfly is closed, it is 100% closed with no exhaust leakage because there are no
orifices (holes) in the butterfly. Remember, the only reason for the orifices in other
exhaust brakes is to keep you from destroying your engine by creating excess pressure at
higher RPMs. Since the "Super Duty" model has a waste-gate bypass, back pressure
is bled off only when necessary.
The waste-gate valve spring is pre-set at the factory to
open only as often and as much as necessary to avoid damage to your specific diesel
Better performance at lower RPMs
The unique design of the "Super Duty" D-Celerator
allows it to build pressure very quickly at lower RPMs. Referring to the chart, notice that because of the waste-gate you can receive
the benefit of maximum back pressure almost all the time without excess pressure. And what
is the benefit? additional braking assistance you can feel in the seat of your
pants almost immediately after the exhaust brake is engaged.
Since most diesel owners ideally run at 1,500 2,000
RPMs, the "Super Duty" model is the clear winner in working with the engine to
provide maximum braking performance.
So if you sometimes tow heavy loads, or drive a large
motorhome, or often drive in hilly or mountainous areas, then the "Super Duty"
D-Celerator is for you. Even if those situations dont describe your driving
patterns, you may decide to use the "Super Duty" model simply to save wear and
tear on your vehicle brakes.
No matter what your situation, we
have an exhaust brake to meet your needs!
Why U.S. Gear?
U.S. Gear is proud to be the only manufacturer to offer two
models of exhaust brakes. The "Standard" model provides effective braking
assistance for light duty applications under non-strenuous conditions. The patented
"Super Duty" D-Celerator renders superior braking support at both low and high
RPMs, and also in extreme environments such as heavy vehicles or loads and mountainous
The D-Celerator advantage includes the fact that both
models are the only computer-controlled exhaust brakes in the industry. This gives U.S.
Gear the freedom to add extra innovations such as the outstanding "cycle
feature." The cycle feature eliminates a problem common to the exhaust brake
industry. Specifically, the cycle feature does away with the soot build-up from diesel
exhaust which causes the butterfly to bind, generally from lack of use.
In addition to their "self-maintenance"
characteristics, stainless steel components also extend the durability of the U.S. Gear
diesel exhaust brakes.
Because all D-Celerators are installed downstream in the
exhaust system where there is more space, U.S. Gears exhaust brakes have an
oversized casting. This means that since the exhaust brake is not in use 95% of the time,
the open butterfly and pivot shaft dont present a barrier to the swirl of diesel
exhaust gases exiting the turbo. In fact, the D-Celerators actually improve flow by increasing
the area available in the exhaust stream.
D-Celerators are available in a wide variety of models
ranging from 2.5" to 4" and either air-activated or electric-activated. U.S.
Gears exhaust brakes are easy to install and are proudly made in the USA.
To top it all off, the D-Celerators are accompanied by the
best warranty in the industry and both models have a 90 day customer satisfaction
Why look anywhere else?
U.S. Gear has more than 35 years of manufacturing experience
and is a recognized leader in the diesel and RV performance industry. The family owned and
managed company uses the most current of todays technology to build products with
old-fashioned values like pride in workmanship and meeting the real needs of
customers. U.S. Gear is not really a corporation as much as it is a group of people just
like you people who work hard and expect extraordinary value in the products they
use. We would never consider producing anything less than the very best.
There's a D-Celerator available for all popular
diesel tow vehicles: Dodge, Ford, Chevy and GMC - trucks, vans, and class "A" or
"C" motor homes. And with dealers nationwide, installation is probably available
in your area before you start your next trip.
CALL TO ORDER 1-800-383-1030
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