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Old 05-18-2022, 11:19 PM   #1
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Charge air Cooler - Inter Cooler (CAC)

I'm not having the best of luck.
I had my CAC replaced less than four years ago. I'm now in a shop in Albuquerque, NM Because my boost dropped 5 PSI while pulling grades and my EGT was also higher. They pressure tested my system and the CAC is leaking near one of the end caps. Haven't see it yet, it will come out tomorrow. This one I'm going to have repaired. Yes I run more boost then stock at 35 psi. This CAC was tested to 50 PSI. I will be looking real close at the mounts and I will also contact Banks to see if I can lower the boost 5 psi. Any thoughts from you guys that know?
Tim
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Old 05-19-2022, 07:19 AM   #2
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Tough luck on the CAC!! Must have been a real bad leak to loose that much boost.



Where did you get the CAC from 4 years ago.







Back 2015 I had a catastrophic radiator failure due to road debris. Since everything was apart I took my CAC to a local shop to have it cleaned and inspected. When they tested it they said it leaked BAD, which I was skeptical of since I was seeing ~22-23 psi boost which is normal for my rig. So I went and had them show me. They put the thing in a large vat of water and put air on it, looked like a Jacuzzi with bubbles everywhere. I had them fix it for $1650. But I only gained a little boost, I sometimes see 24psi now.
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Old 05-19-2022, 09:33 AM   #3
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ISL's run 35psi boost, so, that shouldn't be an issue.
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Old 05-19-2022, 11:03 AM   #4
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Banks responded very quickly and told me how to lower the boost 5 psi. I'm not going to do it until I've been on the road for a while to make sure it's fixed. I agree, 35 psi should not be the problem. I will be looking at the mounts closely when they get it out. I'm not sure who made the CAC, but Massy diesel in Phoenix did the work. At the time the inlet impeller was shot on the turbo so it was rebuilt, I had a cracked exhaust manifold, and the CAC.
Just last NOV I lost the CAPS pump so I added the FASS system. I sure hope this is it for a long time.
Tim
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Old 05-19-2022, 11:07 AM   #5
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Quote:
Originally Posted by 96 Wideglide View Post
ISL's run 35psi boost, so, that shouldn't be an issue.
Earlier ISLs with the CAPPS injector system like Jim and I have although he has an ISC do not run those boost pressures.
I can't say I understand why but we run lower boost numbers.

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Old 05-19-2022, 11:17 AM   #6
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Don't know Ray. Maybe boost increased when they went to variable geometry turbo's .
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Old 05-19-2022, 01:47 PM   #7
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I have a VGT on my ISL370 and on occasion will see maximum boast of 30 psi or a touch over.
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Old 05-19-2022, 02:08 PM   #8
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Where is it leaking from? If it is built for a max of 50 psi and it developed a leak while seeing 35 psi I would be leaning toward either the wrong series of aluminum or improper mounting issues. Do you know what series aluminum it is made from? 70 series aluminum is known to crack rather than flex. 60 series aluminum is much better for items that get hot and cold and have flex issues. Might be worth looking into.
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Old 05-19-2022, 03:24 PM   #9
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Where is it leaking from? If it is built for a max of 50 psi and it developed a leak while seeing 35 psi I would be leaning toward either the wrong series of aluminum or improper mounting issues. Do you know what series aluminum it is made from? 70 series aluminum is known to crack rather than flex. 60 series aluminum is much better for items that get hot and cold and have flex issues. Might be worth looking into.
I have no idea what series and yes 60 series would be better. I don't know who even made it. The flanges are bolted to the frame and bottom has the trans cooler bolted to it so I have asked them to put a strip of rubber in between. That's the only room there is. UPDATE: Massy Diesel is going to call me back with the manufacture's name of the CAC.
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Old 05-19-2022, 08:37 PM   #10
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Update: The CAC is made by CGJ it doesn't say on there website that I can find what series aluminum they use. I will be calling them tomorrow. As it may be a few days before I know if mine can be repaired.
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Old 05-20-2022, 07:38 AM   #11
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Tim,
I had my radiator replaced using a GC&J radiator. I actually sourced the radiator and had Cummins install it. This was in 2015.

I had only put one long trip on my rig before I started building a new house, doing most of the work myself it took a loooooong time.


Fast forward to 2021, finally got the rig ready to travel and took a ~+6k trip from E TN out to SD and looped across the UP of Michigan before heading back.



Got back and while the rig was sitting in my garage it started to seep. I was leaking along the edge. A relatively small amount of coolant. Dr4Film also had a CG&J radiator installed and his had also leaked so I turned to him for advise, he had used IRONTITE to seal it and it had not leaked for several years so I did the same thing.



BUT I had also noticed higher transmission temps, I remember on my first trip in 2015 I had gotten a high temp alarm off my Silverleaf but we were climbing a long grade and I didn't downshift so I figured that was it.
Then on m most recent trips in 2021 I noticed the same thing. Even on short drives when I would back my rig into my new garage I saw temps exceed 230F.

Not good so I emailed my contact at CG&J and inquired about how they sized the transmission cooler in the radiator, the individual did not have a good explanation. He said to put in a bigger one I'd have to remove and send back. He said they could sell me an exterior separate oil cooler for $750, really disappointed in the response.

So I knew that VanWill had completely bypassed his radiator/transmission cooler and installed a separate one, he sent the info on his install. I opted to go with Derale cooler, with a 140F switch to turn the fan on. After a test drive on the interstate doing some decent long grades the temp never higher then 180. Then backing into my garage the temp only increased to ~182 and the fan had yet to kick in so I know I've got plenty of cooling capacity.


In the past I had recommended CG&J but after my experience above I won't recommend them anymore.


Will be interesting to see what they say about your CAC!!
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Old 05-20-2022, 10:34 AM   #12
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Quote:
Originally Posted by Timaz View Post
I have no idea what series and yes 60 series would be better. I don't know who even made it. The flanges are bolted to the frame and bottom has the trans cooler bolted to it so I have asked them to put a strip of rubber in between. That's the only room there is. UPDATE: Massy Diesel is going to call me back with the manufacture's name of the CAC.
Is it leaking by one of the connection fittings at the tank or in one or more of the tubes? I hope that they step up to the plate and make this right for you.
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Old 05-20-2022, 05:37 PM   #13
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Is it leaking by one of the connection fittings at the tank or in one or more of the tubes? I hope that they step up to the plate and make this right for you.
It's leaking where tubes meet the tank, maybe one tube. CGJ said it's past any warranty but would look at it if I sent it to them. I'm on the road so I'm hoping the local shop can fix it. CJG even recommended the shop that has it.
Tim
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Old 05-23-2022, 07:15 AM   #14
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Charge air Cooler - Inter Cooler (CAC)

Quote:
Originally Posted by RamiDav View Post
Earlier ISLs with the CAPPS injector system like Jim and I have although he has an ISC do not run those boost pressures.

I can't say I understand why but we run lower boost numbers.



Ray & Marilyn

03 Windsor

Tim and I both have Banks upgrades which increase boost about 10psi.

I haven’t had any CAC issues… knock on wood. I have a different chassis than Tim, which may mean different mounts and CAC manufacturer. Also lower mileage.
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