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Old 05-17-2012, 10:02 PM   #1
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charger air leak

found a crack in my charge air cooler. Can this be welded or epoxyed? If not, where can I find a new or used unit? Thanks Don 2000 Intrigue w/8.3 Cummins
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Old 05-18-2012, 12:22 AM   #2
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If it's a metal line you can use J-B Weld purchased at Wal-Mart. Clean and sand area. Might put another layer on after first.
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Old 05-18-2012, 12:36 PM   #3
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I would try sealing it up with regular formula JB Weld. If that fails, any radiator shop can possibly repair it or get you a new one. I would not look for a used one as you could be buying one that is about to fail.

The CAC, fan assembly, and radiator can be dropped as an assembly and if you go that far, you should also have the radiator looked at and pressure tested. It is something you want to to once as the assembly weighs about 500 pounds.

Been there done that.
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Old 05-18-2012, 11:55 PM   #4
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It depends where the crack is.

Mine was cracked in the tank. I couldn't consider epoxy because the tank would flex at the crack as the air pressure increased.

I was lucky that the crack was accessible simply by removing the side cover grill. I hired a welder that specialized in aluminum welding. He welded it, added reinforcement to the tank to prevent it cracking again, and pressure tested it.

That was two years ago, and it's been fine ever since.
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Old 06-05-2012, 09:08 PM   #5
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charge air leak

Got my problem fixed. Had good welder do mine. Beautiful job. Thanks for all the help. dcoke
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Old 06-05-2012, 11:22 PM   #6
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I love it when a plan comes together
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Old 06-06-2012, 12:05 PM   #7
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Excellent.

And thanks for reporting back on the solution to the problem.
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