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Old 02-16-2012, 11:33 AM   #1
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Replacing Charge Air Cooler/Trans Cooler Assembly

My Charge Air Cooler is leaking at the input and must be replaced. Specialty Parts in Oregon will sell a new CAC and Transmission Cooler individually, but they must be welded together afterward, with brackets added top and bottom before mounting into a tight fitting space. The Cummins shop doesn't want any part of welding this into an assembly. Before I go have this assembly fabricated and welded, does anyone know where I can find a replacment assembly as shown in the attached picture? Country Coach bought this assembly with the radiator (not shown) bolted onto it. Radiator and Trans Cooler are apparently good.

1997 Country Coach Allure 32'
Cummins 6CTA 8.3 RV 325
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Old 02-16-2012, 12:47 PM   #2
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the input? you mean in the smooth portion of the tank? if so...have it tig welded...any quality welding shop or race car shop can do such a task
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Old 02-17-2012, 06:06 AM   #3
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Not weldable apparently

Here's what the Cummins Service Rep told m:
"It is leaking at several core tubes on the ends that are welded to the tanks and some of the tubes leaking in the middle of core. When we have sent these type of issues out in the past to have repaired and they would not be able to repair them. They would say to replace and they would not warranty repair."

The engine is being replaced with a reconditioned engine. The recon engine warranty requires that the CAC must meet spec, so that is why we tested it in the first place. Thanks for the great reply though, it caused me to revisit repairing it. This is a very unwelcome development on top of replacing the engine, at least a $4K addition.
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Old 03-16-2012, 07:20 AM   #4
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Here is a picture of the latest CAC assembly I've received. The air tube is damaged. Also, it has been painted inside and out. Is it accaptable to paint the inside of this assembly?
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