Help! Charge Air Cooler

[2racer]

Since finding this website, I sure have been needy. I hope I will be able to enjoy it and at least one day help others, but currently I need help again.
Today the coach lost power, it was drivable, but no get up and go. I got it to Cummins and they've just informed me that it's the charge air cooler. The problem is that they are saying it will be 6 to 8 weeks before they can get one! I've called the factory and left numerous messages, but can't get anyone on the phone to see if they will pull one off the production line to save me. What horrible timing, I'm in MS, my wife and kids are in FL and we're due to leave for NC on the 26th. Any ideas? Please call me on my cell if you can @ 850 723-1089. Mindy had to post this from home, I'm computerless. Heath

[2racer]

Since finding this website, I sure have been needy. I hope I will be able to enjoy it and at least one day help others, but currently I need help again.
Today the coach lost power, it was drivable, but no get up and go. I got it to Cummins and they've just informed me that it's the charge air cooler. The problem is that they are saying it will be 6 to 8 weeks before they can get one! I've called the factory and left numerous messages, but can't get anyone on the phone to see if they will pull one off the production line to save me. What horrible timing, I'm in MS, my wife and kids are in FL and we're due to leave for NC on the 26th. Any ideas? Please call me on my cell if you can @ 850 723-1089. Mindy had to post this from home, I'm computerless. Heath

[Old Scout]

Unfortunately, there aren't too many good options for you. You didnt mention your coach year but assume the charge air is the same/ similar to our 2003 and was made by Radiator Specialists (RS)in Sacramento Ca. (Yup-same as the "new" aluminum radiator guys). Dont think WRV has any coaches in production right now. Also, there are atleast two different models of C/As--I know because they shipped me the wrong one the first time (make sure you get the exact measurements to RS). I also had trouble getting RS to release a C/A directly to me without WRV approval, claiming the part was propriotary to WRV. It took about two weeks to get a replacement C/A--not counting the first two week we waited for the wrong model to arrive. As I recall, the C/A was about $1800 and another $450 shipping to Tx...

[Cruzer]

In a worse case scenario I'd see if they could bypass it. Take the hose that feeds it and connect it direct to the hose coming out via a piece of steel exhaust tubing. If your charge air cooler leaks you'll lose all your boost and your power drops drastically, as you already found out . It's purpose is to cool the incoming air so that it is denser. By bypassing it you won't get cold air but at least you won't have any leaks and you should be able to make it home. 80% power is a lot better than 15%. At least you can get home and bebetter equipped to service it at your convenience.

[2racer]

Thanks for the info, Mark at WRV was able to get a new CAC for me and shipped out to cummins in Jackson, Ms. Great thanks to Mark Harrah at WRV service center for handling this issue so quickly as my rig is a integral part of my business and 6-8 weeks down time would cost me greatly.I have left the rig in Jackson and returned home for Christmas, the CAC should be in Jackson on WEd. after Christmas when Cummins reopens. I'm not so sure I won't go back and make the swap myself even if I have to do it in a truck stop parking lot. I'm going to make a few calls to guys that I race with in the area and see just how close they are to the rig's location to maybe borrow a driveway or something. I've had the power steering cooler out for repair after a tire blowout(ripped the weld bung clean out of the side of the tank)and it doesn't appear to be much more work to get the CAC swapped out. Or is it ?!?
Thanks again for all info.
THanks Cruzer for viable option by by-passing. I have the world's largest "toad"(not kidding) so how would that have been on the engine without cooler?
Thanks for the call Dean, crossing my fingers for right size.

[Cruzer]

That's great news, certainly better than 6-8 weeks. Running warm air into the engine won't let it run at max power but it would have been better than no boost. If you did get to a severe long grade where it really got hot the engine would sense that and derate the power output so you wouldn't hurt anything.

[2racer]

Here's a little tip if you ever lose power in your RV,when the shop says you need a charge air cooler ask them to check other possibilities LIKE THE PAC-BRAKE NOT DISENGAGING/GETTING STUCK!!! Just spent alot of$$$$ for a part that was not my problem. Yes the CAC was leaking but it had been leaking apparently from a tire blowing out and striking the power steering cooler(which mounts to the bottom of the CAC) many many months ago. I sure hope I notice a power gain, I could have litterally chewed titanium nails when I trest drove the rig down the road and the same issue existed. This is just like racing -it is VERY EXPENSIVE TO LEARN RVlessons, hopefully I can save at least one person from getting caught in this same scenario. Now I not only have to fix the HACK JOB performed by the mechanic cutting out the aluminum panel around the CAC(new stlyle CAC required opening up the area a bit) I get to install the part I actually need.