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Charge Air Cooler seam split

December 22, 2016, 05:00:16 pm

We have developed a crack (actually a seam split along the weld on the forward side) in our charge air cooler in our '95 U320 .  Is there an easy fix short of having the entire package removed?  Cummins in Coberg, OR will do the work, but it will be pricey and with an unknown length of down time.  Two years ago we had a similar "crack" just above the current one and I used JB Weld on it and it appears to still be OK.  I know the consequences of a major failure here, but anyone have any other thoughts?

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Re: Charge Air Cooler seam split

Reply #1 – December 22, 2016, 05:03:28 pm

Not sure how it is configured, maybe a welding shop with a Tig welder could get to it. Just a thought.

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Re: Charge Air Cooler seam split

Reply #2 – December 22, 2016, 05:59:33 pm

Usually after welding, the intercooler is cleaned so there is no risk of a metal particle getting into the engine. Welding in place won't let you do that. Not sure what the chances are but any kind of engine damage is VERY pricy. You might consult Cummins for risks.

I have used JB Weld on lots of occasions with great success.

Pierce

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Re: Charge Air Cooler seam split

Reply #3 – December 22, 2016, 06:44:51 pm

A few years ago I repaired 3 good size holes in ours with Devcon metal paste. It is made for exactly that fix and I have used it many years ago in engine block casting problems. It can be filed,drilled, machined and is simple to use. You MUST take a CAC off to do a correct fix as it needs to be flushed out with water to remove any debris that MAY be there. I was told by a very qualified Alum welding shop that they would never recommend welding CACs due to the carbon build up inside. So, it is easy to remove usually and maybe this is the best non expensive way to do it.. post a picture of the problem area and I will see if my method will work for you. I also used a piece of aluminum sheet bent to fit tight over the crack once a dab of the Devcon was brushed over holes. The area to be fixed needs to be wire brushed/sanded to clean it up before using the filler.
JohnH

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Re: Charge Air Cooler seam split

Reply #4 – December 22, 2016, 06:54:06 pm

I removed ours to have 3 of the 4 tabs (that hold the CAC to the radiator) welded back on. Only 1 was left holding it to the raidiator frame. The rest of the cooler was held in place by the rubber shroud.
 Really wasn't that tough to remove and it gave me a chance to clean the pipe, clamps, fittings and all that.

 Now I understand how I will be implementing the water cooler that RRadio did.

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Re: Charge Air Cooler seam split

Reply #5 – December 22, 2016, 07:35:55 pm

If JB weld or similar will hold, use that!  It's not a big deal if you get a failure. You'll loose power and not run well, but nothing will blow up.

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Re: Charge Air Cooler seam split

Reply #6 – December 22, 2016, 10:14:32 pm

I would use Devon over JB weld. Great product.

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Re: Charge Air Cooler seam split

Reply #7 – December 23, 2016, 04:35:36 am

If you go that route reseach a product called "belzona",much better then jb weld,have used it to repair the inside of engine blocks
and water pumps.

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Re: Charge Air Cooler seam split

Reply #8 – December 23, 2016, 09:33:49 am

Belzona is a brand, with different products. It can be very expensive. But the ceramic stuff will hold up better than steel in many cases! We use it a lot in industry.

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Re: Charge Air Cooler seam split

Reply #9 – December 23, 2016, 11:19:24 am

It is pricey,we have used the formula in the orange container,have personally repaired things from aluminum carburaeters to
the inside of engine block liners after they develope a pinhole also water pump housings.

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