The BD Diesel 1027145AP is a complete remote-mount, air-actuated inline exhaust brake and transmission pressure management 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, 5R110 TorqShift automatic transmission, and the stock 3.5-inch exhaust system. Built around a heavy-duty cast-iron housing with a stainless steel butterfly shaft and alumibronze bushings, this kit integrates BD’s exclusive Variable Orifice Technology (VOT) with a dedicated onboard 12V air compressor and a specialized TorqShift transmission control module. By coordinating mechanical backpressure with electronic torque converter clutch lockup and elevated line pressures, the system generates up to 150 retarding horsepower directly through the automatic drivetrain without transmission slippage.

Terrifying brake fade on steep grades, glazed brake pads, warped rotors when hauling heavy fifth-wheel trailers, transmission overheating from torque converter slippage during downhill coasting, and minimal engine retarding from the stock VGT turbo are what this complete kit cures. When an exhaust brake closes on an automatic transmission without lockup control, the torque converter slips, dissipating the braking power into fluid heat and letting the truck run away on descents. The BD 1027145AP package solves this by pairing the inline pneumatic butterfly valve with an electronic transmission control module that commands converter lockup and boosts internal clutch clamping pressure whenever the exhaust brake engages. This mechanical connection transfers retarding horsepower through the drivetrain to hold speeds securely, keeping service brakes cool for emergency stops. It is a complete automatic transmission exhaust brake system configured for the stock 3.5-inch exhaust, including the remote brake valve, onboard air compressor, air tank, transmission pressure module, wire harnesses, and hardware; trucks equipped with an aftermarket 4-inch exhaust require kit 1027146AP.

It fits 2003–2007 Ford F-250, F-350, F-450, and F-550 Super Duty trucks as well as 2003–2005 Ford Excursions equipped with the 6.0L Powerstroke diesel, 5R110 TorqShift automatic transmission, and factory stock 3.5-inch exhaust system (not for ZF6 manual transmissions; not for aftermarket 4-inch exhaust systems).

Fitment

• 2003–2007 Ford F-250 Super Duty 6.0L Powerstroke (5R110 Automatic / Stock Exhaust)
• 2003–2007 Ford F-350 Super Duty 6.0L Powerstroke (5R110 Automatic / Stock Exhaust)
• 2003–2007 Ford F-450 / F-550 Super Duty 6.0L Powerstroke (5R110 Automatic / Stock Exhaust)
• 2003–2005 Ford Excursion 6.0L Powerstroke (5R110 Automatic / Stock Exhaust)
• Fits factory stock 3.5-inch exhaust tubing (remote-mount inline configuration)
• Engineered specifically for 5R110 TorqShift automatic transmissions
• Includes electronic transmission pressure controller to lock torque converter and prevent clutch slippage
• Variable Orifice Technology (VOT) generates up to 150 retarding horsepower across the entire RPM range
• Heavy-duty cast-iron housing with stainless steel butterfly valve and alumibronze bushings
• Includes dedicated heavy-duty 12V onboard air compressor, pressure regulator, and air reservoir tank
• Pneumatic spring-loaded actuator ensures fail-safe open valve positioning when disengaged
• Includes in-cab dash switch, throttle pedal position sensor harness, wiring loom, and mounting hardware
• Complete stock exhaust brake system package with transmission lockup controls

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 downstream of the transmission crossmember, verifying clearance around fuel lines, brake cables, and wiring looms. Cut out the marked section cleanly with a reciprocating saw or pipe cutter, thoroughly deburring the inside and outside edges of the cut pipe. Slide the supplied 3.5-inch adapter flanges over the factory pipe ends, position the cast-iron BD brake valve in line with the exhaust flow arrow pointing toward the tailpipe, and torque the heavy-duty V-band clamps securely. Mount the 12V air compressor and reservoir tank to the frame rail using the rubber vibration isolators, routing the nylon air lines to the pneumatic actuator cylinder and electric control solenoid. Under the hood and inside the cab, tee the BD electronic transmission pressure harness inline with the factory PCM and transmission wiring harness connectors, ensuring the throttle position sensor (TPS) circuit is connected so the brake valve instantly opens when the accelerator is depressed. Mount the in-cab control switch on the dashboard, connect the fused 12V power leads, reconnect the batteries, and road test the truck under closed-throttle deceleration to verify torque converter lockup and positive retarding performance.