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Topic: Need Charge Air Cooler replacement advice for 2000 Affinity (Read 1343 times) previous topic - next topic
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Need Charge Air Cooler replacement advice for 2000 Affinity

Yahoo Message Number: 63736
I have a crack in the Charged Air Cooler (CAC)of my 2000 Affinity, CC:5801, so can only get half the normal turbo boost and half the HP from my CAT-12. I know from friends and from previous messages that a lot of CC users - and other brands - have had radiator failures, so I would like advice or suggestions from similar year or similar experience owners to avoid a possible repeat failure of my CAC.
I have not removed the cracked CAC (or radiator assembly) yet to find the RS tag and number, but Country Boys and others assure me my CAC was manufactured by J.B. Radiator Specialties, Inc. in Sacramento. I can visually see that it has another tank bolted to the bottom of the CAC with a hose from my hydraulic fluid (steering) reservoir. We are back in SC now, but the Service Mgr at Wagner CAT who just worked on my C-12 and discovered the "crack" said over the years they have had to replace a lot of J.B. radiators under warranty for CC. Same was true for other brands as well per CC management.
I'm told CC changed suppliers for CACs and radiators from J.B. to AKG in NC due to the failure rate of J.B. equipment, but AKG completely changed the design to include "mounting" and it is a major job to change - not a simple retrofit and thus not a viable solution. This change took place maybe in 2007 and the next year or so after CC no longer had a relationship with J.B., another company, Radiator Supply House, was furnished CC drawings and/or specifications so that they could help resolve CC owners "radiator" issues one-on-one without CC being in the middle - obviously part of the financial mess. So, Radiator Supply House started manufacturing their designed direct replacement radiators and CACs for CC owners to order and at some point J.B. changed their manufacturing process to a "gasket/sealant/bolt-on-tank" method.
My choices today are to TIG weld/repair the crack (which most people tell me is virtually guaranteed not to hold)or 2. replace with a newly manufactured J.B. CAC from Source Manufacturing, OR (their distributor); 3. have Radiator Supply House "weld" a new CAC; or 4. buy one of the CC new surplus "bolted together" radiators built by J.B. after they changed design. (Radiator Supply House purchased the "bolt together" CACs from CC apparently at the bankruptcy auction.)
The president of Radiator Supply House told me that so far, he has only had to replace one J.B. radiator which he sold and failed and it happened to be a welded type, however conventional wisdom had been in favor of welded CACs and that is how they manufacture for their own brand.

Again any wisdom or experience will be appreciated.
I also have issues with an erratic 42 series Kiwikee step which I suspect is a "controller" issue. If anyone has comments or experience on this, I would also like to hear, but it probably should be listed as a new topic. Apparently Kiwikee ownership has changed hands, moved to Indiana, and stopped all means of direct customer support. I'm also told they no longer offer a controller supporting a "normally-open" door jam switch so you now have to buy a conversion package for over $300 which includes a new controller and motor and a change-out of the door jam switch.

Thanks for your responses.

Kent and Dale McCoin, 2000 Affinity #5801 H: 803-364-2911
C: 803-318-0071

kmccoin@...

Re: Need Charge Air Cooler replacement advice for 2000 Affinity

Reply #1 –
Yahoo Message Number: 63737
You might want to check with these folks in Gadsden, Alabama
http://www.cgj.com/bricethomas.asp
If you do a topic search on this group you will find references indicating that Brice Thomas is able to handle CC radiators and CAC's at lower cost and quick turnaround. I have not used them but do have them in my reference file for the next time I need that type service.
Early on, I had to have the CAC replaced, twice, the most replacement was around 6 years ago.

Ray

2000 Intrigue 11040

Re: Need Charge Air Cooler replacement advice for 2000 Affinity

Reply #2 –
Yahoo Message Number: 63751
Ray,

Thanks for the referal to CGJ. I called the folks in Gadston and sent them an email picture of the visible crack in the tank portion of my CAC. They are to call me back if they think they might be able to handle my case. They said normally the tanks are good so they reuse them and replace the "core." They don't have new tanks so they will let me know what is possible.
Ray, did you replace your CAC with J.B. Radiator Specialties products both times, and if so, were they both using the same metal thickness, etc.?
Just got a call back from CJG who says my picture shows the crack is in the "header" which is part of the "core." Therefor they can recore it for less than the cost of a new CAC and cover it with a 1 year parts and labor, unlimited mileage, guarantee. Sounds much better to me! Thanks again!

Kent & Dale McCoin, 2000 CC Affinity, #5801

Re: Need Charge Air Cooler replacement advice for 2000 Affinity

Reply #3 –
Yahoo Message Number: 63759

I would prefer a rebuilt exchanger from someone like CGJ. The workmanship is certainly going to exceed the mass produced junk being sold as replacements and OEM for that matter. The new one should last indefinitely.

Bob (rthandren@...)
'05 Inspire 51178

Re: Need Charge Air Cooler replacement advice for 2000 Affinity

Reply #4 –
Yahoo Message Number: 63814
Hi Friend, Im a retired Caterpillar Service tech, A fellow CCer has a 00 with a c-12 cat. He came to Yuma whare I winter with his coach. He had a crack on his CAC. We used a Digital camera and took photos of the crack, Luckly the crack was on the housing behiend the rock grate outside. We headed to a welding shop in Yuma a showed the Welder the photos. He said bring in the motorhome and I will run a bead over the crack. He did and for 50 dollars, I said to my friend tip him another 20 dollars! Working on Diesels all my life I would pull CAC's and have our welding shop repair or send it out to the radietor shop. If the crack is acessable just get it welded! Hope this helps, Ken Retired Cat Tech. 99 Allure 30356. Trust me there are good welders out there!

Re: Need Charge Air Cooler replacement advice for 2000 Affinity

Reply #5 –
Yahoo Message Number: 63819
Yes, both were replaced using J.B. Radiator Specialties products but I don't know if they were different thickness or not.

Glad you are getting positive response from CGJ.

Good luck with the fix.
Ray

2000 Intrigue 11040

Re: Need Charge Air Cooler replacement advice for 2000 Affinity

Reply #6 –
Yahoo Message Number: 64013
You might look at this company for a CAC I replaced mine last December with this Brand. Your right about RS being bad design, your also right about the oil cooler welded to the CAC. I changed mine to a bolt on oil cooler. I would recommend pulling the CAC and taking good measurements before buying a new one from DURA LITE. I did not do that and the fit was not perfect but it was acceptable. I changed all turbo couplings and hoses; Coolant, hydraulic. DURA-LITE engineers are very good at making a fit. The do have some CC coolers and a bunch of Monaco coolers.
By the time I was done the cost was $5300.00, with the cooler costing about $2200.00, the rest was parts, fluids and labor.

WW Williams did the work in Tucson, AZ they did a good job.
http://www.duralite.net/contact.html
Jack Allure 30076