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Charge Air Cooler Rebuild

Yahoo Message Number: 19045
Wow Ray, I hope that I do not have two more Bad news to go thru. Our repair insurance (DFS Advantage) is bulking at the $2,900 new unit. They want to have it rebuilt by MAC raditor in Portland. Cummins NW Service folks say they have had Good Luck with the MAC rebuilts. We will still be out of our rig for two weeks. That is a long time for full timers. Hey, you other Full timers, do you have a plan if you are out of you Coach for an extended time?????? Lee Casebeer, in Portland with broken '01 Intrigue #11219

Re: Charge Air Cooler Rebuild

Reply #1 –
Yahoo Message Number: 19047
We have had 2 other motorhomes and our Magna has more problems then the Fleetwood or Rexhall. We have been fulltiming 10 years. We bought the Magna in May 05.
Laura/Magna 5874

Yea, the second time I have a radiator problem, the coach is going up for sale and I'm going back to a fifth wheel.

Bob

Re: Charge Air Cooler Rebuild

Reply #2 –
Yahoo Message Number: 19048
Has anyone taken any photos of the cracks and problem areas? Sure would be interesting to look at. I just finished a trip from Florida to Alaska and back and no problem yet at 53k miles. Of course, every time I was the coach I make sure I flush out the radiator and CAC area to get rid of grit. Small rocks are no longer a problem since I screened in the lower half of my fan. I just put a couple of photos up in my folder KC4FWS.

Jim Hughes

2000 Allure #30511

Quote from: Bob Stephens
Yea, the second time I have a radiator problem, the coach is going > up for sale and I'm going back to a fifth wheel.

Bob

Quote from: lcasebeer@c...

>

> Wow Ray, I hope that I do not have two more Bad news to go

thru.

Quote
Our repair

> insurance (DFS Advantage) is bulking at the $2,900 new unit.

They

Quote
want to have

> it rebuilt by MAC raditor in Portland. Cummins NW Service folks > say they have

> had Good Luck with the MAC rebuilts. We will still be out of our > rig for two

> weeks. That is a long time for full timers. Hey, you other Full > timers, do you

> have a plan if you are out of you Coach for an extended

time??????

Re: Charge Air Cooler Rebuild

Reply #3 –
Yahoo Message Number: 19049
The CAC is a defective product that could not hold the pressure of the turbo. Laura/Magna 5874

Has anyone taken any photos of the cracks and problem areas? Sure would be interesting to look at. I just finished a trip from Florida to Alaska and back and no problem yet at 53k miles. Of course, every time I was the coach I make sure I flush out the radiator and CAC area to get rid of grit. Small rocks are no longer a problem since I screened in the lower half of my fan. I just put a couple of photos up in my folder KC4FWS.

Jim Hughes

2000 Allure #30511

Re: Charge Air Cooler Rebuild

Reply #4 –
Yahoo Message Number: 19073
Hi Jim,

Your screen approach looks very well thought out and professionally installed.

If the CAC fails in our coach, I will first try an aircraft epoxy repair - total cost about $50. I have built a Longeze and repaired several of the same, all are fiberglass and epoxy, and would be very positive of a secure repair using carbon fiber cloth and aircraft grade epoxy.
Fred Kovol

2000Allure30593

Re: Charge Air Cooler Rebuild

Reply #5 –
Yahoo Message Number: 19076
Jim,

I couldn't see any cracks on mine, they removed it and pressurized it and put it in liquid to find the leaks. Very fine hairline cracks on upper radius of the CAC so no stones involved. It appears to have been a manufacturing flaw from the CAC vendor, they made good on replacement with me paying freight and labor on the first one. The 2nd second one was discovered by Cummins SE in Tampa, they sprayed some soapy water on the CAC and got bubbles, again the cracks were so fine you could not see them. I also had a cracked manifold with that one. The manifold was replaced under Cummins warranty.

Ray

2000 Intrigue

Quote from: Jim Hughes
Has anyone taken any photos of the cracks and problem areas? Sure > would be interesting to look at. I just finished a trip from > Florida to Alaska and back and no problem yet at 53k miles. Of > course, every time I was the coach I make sure I flush out the > radiator and CAC area to get rid of grit. Small rocks are no

longer

Quote
a problem since I screened in the lower half of my fan. I just

put

Quote
a couple of photos up in my folder KC4FWS.

Jim Hughes

2000 Allure #30511

[quote author=Bob Stephens"

>

> Yea, the second time I have a radiator problem, the coach is

going

Quote
up for sale and I'm going back to a fifth wheel.
>
> Bob
>
>
>

> -

Re: Charge Air Cooler Rebuild - Now Symptoms of Problem

Reply #6 –
Yahoo Message Number: 19077
What was your rig doing that caused the search for the cracks to begin?

Dean

95 Magna 5280

Quote from: travman100
Jim,

I couldn't see any cracks on mine, they removed it and pressurized > it and put it in liquid to find the leaks. Very fine hairline

cracks

Quote
on upper radius of the CAC so no stones involved. It appears to

have

Quote
been a manufacturing flaw from the CAC vendor, they made good on > replacement with me paying freight and labor on the first one. The > 2nd second one was discovered by Cummins SE in Tampa, they sprayed > some soapy water on the CAC and got bubbles, again the cracks were > so fine you could not see them. I also had a cracked manifold with > that one. The manifold was replaced under Cummins warranty.

Ray

2000 Intrigue

[quote author=Jim Hughes"

>

> Has anyone taken any photos of the cracks and problem areas?

Sure

Re: Charge Air Cooler Rebuild - Now Symptoms of Problem

Reply #7 –
Yahoo Message Number: 19078
'Dean,

While we were at the CC Reunion a few months ago we had one of the techs check to see if we had a crack and we did but not where they usually are. Our crack was on the left front side, while our friends crack is on the right side. We bought this Magna with this problem I wish we would have know to look for it before we bought. ' Laura/Magna 5784

Re: Charge Air Cooler Rebuild

Reply #8 –
Yahoo Message Number: 19080
Hey Fred,

What is the CAC material? Is it a graphite composite? If so, I have some experience working with composites on military aircraft such as the F/A-18 Hornet.

Jim Hughes

2000 Allure #30511

Quote from: fredkovol

Re: Charge Air Cooler Rebuild - Now Symptoms of Problem

Reply #9 –
Yahoo Message Number: 19081
So what are the symptoms? Were you loosing coolant? Was the leak obvious?

Jim Hughes

2000 Allure #30511

Re: Charge Air Cooler Rebuild

Reply #10 –
Yahoo Message Number: 19088
Hi Jim,

No, I don't know the CAC material - I guess it might be aluminum alloy. You have a choice of glass which works well with any metal - E glass, S glass, kevlar, graphite and ceramic; all of this and the aircraft epoxys can be found at
www.aircraft-spruce.com
Fred Kovol

Quote from: Jim Hughes"
[quote
uote] >]
Hey Fred,

What is the CAC material? Is it a graphite composite? If so, I

have

Quote
some experience working with composites on military aircraft such as > the F/A-18 Hornet.

Jim Hughes

2000 Allure #30511

[quote author=fredkovol"

>

> Hi Jim,

> Your screen approach looks very well thought out and
professionally

Quote
installed.

> If the CAC fails in our coach, I will first try an aircraft epoxy > > repair - total cost about $50. I have built a Longeze and repaired > > several of the same, all are fiberglass and epoxy, and would be

very
 

Re: Charge Air Cooler Rebuild - Now Symptoms of Problem

Reply #11 –
Yahoo Message Number: 19091
Black smoke, they were checking everything that might cause the black smoke. That problem was not fixed by replacing the CAC. The black smoke problem was eventually fixed when Cummins replaced all the injectors.
Ray

2000 Intrigue

Quote from: Dean
What was your rig doing that caused the search for the cracks to > begin?

Dean

95 Magna 5280

[quote author=travman100"

>

> Jim,
>

> I couldn't see any cracks on mine, they removed it and

pressurized

Quote
it and put it in liquid to find the leaks. Very fine hairline > cracks

> on upper radius of the CAC so no stones involved. It appears to > have

> been a manufacturing flaw from the CAC vendor, they made good on > > replacement with me paying freight and labor on the first one.

The

Quote
2nd second one was discovered by Cummins SE in Tampa, they

sprayed

Quote
some soapy water on the CAC and got bubbles, again the cracks

were

Quote
so fine you could not see them. I also had a cracked manifold

with

Quote
that one. The manifold was replaced under Cummins warranty.
>
> Ray

> 2000 Intrigue
>

[quote author=Jim Hughes"
>]
> >

> > Has anyone taken any photos of the cracks and problem areas? > Sure

> > would be interesting to look at. I just finished a trip from > > > Florida to Alaska and back and no problem yet at 53k miles.

Of

Quote
> course, every time I was the coach I make sure I flush out the > > > radiator and CAC area to get rid of grit. Small rocks are no > > longer

> > a problem since I screened in the lower half of my fan. I

just

Quote
put

> > a couple of photos up in my folder KC4FWS.
> >

> > Jim Hughes

> > 2000 Allure #30511
> >
> >
> >

[quote author=Bob Stephens"
> >]
> > >

> > > Yea, the second time I have a radiator problem, the coach is > > going

> > > up for sale and I'm going back to a fifth wheel.
> > >
> > > Bob
> > >
> > >
> > >
> > >

[quote author=lcasebeer@c...
>]
> > > >

> > > > Wow Ray, I hope that I do not have two more Bad news to

go

Quote
> thru.
> > > Our repair

> > > > insurance (DFS Advantage) is bulking at the $2,900 new

unit.

Quote
> They
> > > want to have

> > > > it rebuilt by MAC raditor in Portland. Cummins NW Service > > folks

> > > say they have

> > > > had Good Luck with the MAC rebuilts. We will still be out

of