2012 Ford F-450 CAC (charge air cooler) failure
For RV'ers with an earlier models Ford trucks (2011 - 2016 model) with the 6.7L diesel engine, there is a "Customer Satisfaction Program - 18M03" for the CAC (charge air cooler) outlet tube that is on the high pressure side of the turbocharger. The program extends the warranty for that part to a total of 10 years from the date of original purchase of the truck. However, the part has to fail before it is covered.
The CAC outlet tube is a plastic-like fitting that could become brittle and fail. That is what happened to my truck. Around 6:30 PM, on my way from storage to park the trailer at a local RV park, there was a loud bank under the hood followed by a loud exhaust sound under the hood, the turbocharger gauge dropping to nothing, and the engine losing power. The truck could not be moved because the engine had trouble idling much less pulling a load. I ended up stuck on the side of the road on I-20 in Fort Worth, at a very dangerous spot known for people running over each other.
As for the repair, in my case, it took the Ford truck shop an hour to do the paperwork and pull the part from stock, and 15 minutes to remove and replace the part. Didn't cost me a thing.
However, it was not fun spending 6 hours on the side of the road plus another hour getting the trailer back to storage and the wrecker service to haul my F-450 and a 5th wheel trailer was pricey. Because the truck and trailer were being delivered to two separate locations, the tow required two wreckers, a heavy tow truck for the trailer and a flatbed for the truck. Also, the F-450 had to be towed the next day to the dealership. The total cost was well over $1,000.00.
It may be worth those with a similar vehicle to look into whether your truck is also under the "Customer Satisfaction Program - 18M03". If so, looking into replacing the part proactively, either by a dealership/repair shop or by yourself, could save a lot of money the long run. The CAC looks like a simple repair and handyman could do it. Had I known this, I would have replaced it myself.
I noticed the part online and some upgrade kits as well, but didn't further research or look at the prices. A little too late for that.
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Carl and Janis
2013 Excel L36GKE
2012 Ford F450 w/Highwayman RV Hauler
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