Detroit Diesel — Turbo Brake Disassembly Procedure

Repair & overhaul · Turbo brake assembly / turbocharger

From a Detroit Diesel service manual — check it applies to your exact model before use.

Procedure

1. Remove the clevis pin from the ball socket on the sliding sleeve actuator and discard.
2. Using a large screw driver or pry bar, disconnect the sliding sleeve actuator ball socket from the sliding sleeve lever.
3. Inspect the sliding sleeve actuator for damage or binding and try to move the sliding sleeve lever.
4. Remove the two bolts (1) and v-band clamp (3) from the exhaust bypass pipe (2); discard the two bolts, but save pipe and clamp.
5. Remove the four (4) nuts holding the brake assembly to the housing and discard.
6. Separate the assembly from the turbocharger housing. Set the turbocharger horizontally on a sturdy table. Protect the speed sensor and wiring from damage.
7. Using a brass hammer, tap the turbocharger housing equally on two sides until a small gap is generated; do NOT hit the exhaust pipe connecting flange.
8. Use a large screwdriver or pry bar to apply even leverage 180° apart to separate the brake from the turbocharger housing; keep the brake assembly as straight as possible.
9. Use an emery cloth to clean the edge of the turbocharger housing just above the Matrix lip. Do NOT use a die grinder or a powered sander.
10. Apply a small amount of penetrating oil just above the Matrix lip around the entire radius and allow it to set for a few minutes.
11. Grab the Matrix with two hands and rotate it back and forth while pulling straight up; lightly tap the TOP with a rubber mallet to re-seat it if it binds.
12. Use a non marring strap wrench near the base for extra leverage if the Matrix will not turn by hand. Do NOT hit the side of the Matrix.
13. Inspect the turbine blades for wear, cracks, chips, or evidence of foreign material entering the turbocharger.
14. Inspect the inside of the housing for single or multiple cracks. The housing can ONLY be reused if the cracks do not intersect.
15. Use an emery cloth and clean all mating surfaces between the housing and the new brake assembly.

Source: Detroit Diesel service manual. Steps and values are as documented; always cross-check against the official manual and any later revisions for your exact serial number before servicing.

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