The BD Diesel 1027145 is a remote-mount, air-actuated inline exhaust brake kit engineered for 2003–2007 Ford F-250, F-350, F-450, and F-550 Super Duty trucks equipped with the 6.0L Powerstroke diesel, a 6-speed ZF6 manual transmission, and the factory stock 3.5-inch exhaust system. Designed to install directly into the stock exhaust tubing downstream of the downpipe, this kit features a heavy-duty cast-iron housing, a stainless steel butterfly shaft, and durable alumibronze bushings. BD Diesel pairs this assembly with their exclusive Variable Orifice Technology (VOT), a dedicated onboard air compressor, and a spring-loaded pneumatic cylinder to regulate exhaust backpressure across the engine’s entire RPM range—producing up to 150 retarding horsepower without requiring an aftermarket 4-inch exhaust.

Severe service brake fade on steep grades, glazed brake pads, overheated front rotors when towing heavy gooseneck trailers, and minimal engine retarding from the stock VGT turbo are what this inline mechanical brake cures. On manual ZF6 trucks, relying solely on downshifting and friction brakes builds excessive brake heat that risks total braking loss on mountain descents. The BD 1027145 creates controlled exhaust backpressure by closing a precision butterfly valve when the driver lifts off the throttle, transferring braking force directly to the engine pistons to hold vehicle speed check. This preserves friction brakes for complete emergency stops. It is a complete inline exhaust brake kit configured for the stock 3.5-inch exhaust on manual transmission trucks, including the remote brake valve, onboard 12V air compressor, air tank/lines, microswitches, and mounting hardware; trucks equipped with an aftermarket 4-inch exhaust require kit 1027146.

It fits 2003–2007 Ford F-250, F-350, F-450, and F-550 Super Duty trucks equipped with the 6.0L Powerstroke diesel, 6-speed ZF6 manual transmission, and the stock 3.5-inch exhaust system (not for 5R110 automatic transmissions unless using the 1027145AP kit with an AutoLoc lockup module; not for 4-inch exhaust systems).

Fitment

• 2003–2007 Ford F-250 Super Duty 6.0L Powerstroke (ZF6 Manual / Stock Exhaust)
• 2003–2007 Ford F-350 Super Duty 6.0L Powerstroke (ZF6 Manual / Stock Exhaust)
• 2003–2007 Ford F-450 / F-550 Super Duty 6.0L Powerstroke (ZF6 Manual / Stock Exhaust)
• Fits factory stock 3.5-inch exhaust tubing (remote-mount inline configuration)
• Engineered specifically for ZF6 6-speed manual transmissions
• Variable Orifice Technology (VOT) generates up to 150 retarding braking horsepower
• Rugged cast-iron valve housing with corrosion-resistant stainless steel butterfly and shaft
• Includes dedicated heavy-duty 12V onboard air compressor, regulator, and air tank
• Pneumatic spring-loaded actuator ensures fail-safe open valve positioning when disengaged
• Includes in-cab dash switch, throttle/clutch pedal position switches, wiring harness, and hardware
• Complete stock exhaust brake system package

Park the truck on a solid, level surface, set the emergency brake, and disconnect both negative battery cables. Measure and mark a straight 7- to 8-inch section of the factory 3.5-inch intermediate exhaust pipe along the frame rail behind the transmission crossmember, verifying clear routing away from fuel lines and brake cables. Cut the section out cleanly using a reciprocating saw or pipe cutter, and deburr the inside and outside edges of the cut pipe thoroughly. Slide the supplied 3.5-inch exhaust adapter flanges over the factory pipe ends, position the cast-iron BD brake valve inline with the exhaust flow arrow pointing toward the tailpipe, and torque the heavy-duty V-band clamps securely. Mount the 12V air compressor and air reservoir tank to the frame rail using the included isolation mounts, routing pneumatic nylon lines to the brake actuator cylinder and electric control solenoid. Under the dash, install the throttle switch and clutch pedal disengagement switch so the brake valve instantly opens the moment the accelerator or clutch pedal is depressed. Route the master power toggle switch to the dashboard, hook up the 12V fused power harness, reconnect the batteries, and road test the vehicle under closed-throttle coasting to confirm positive retarding operation.