Engine/Transmission (1998.5 - 2002) Charge Air Cooler Failure(Dealer Ripoff?)

[Cjulius]

Okay, here goes nuthin' First time post here. I have a stock 2001 Quad Cab 2500. The short story is it started to smoke (billow) white clouds one day. Power was erratic, RPM was erratic, the whole thing would just shudder for a bit... then miraculously(?) cure itself and run fine. The dealer said it had no Boost pressure and the intercooler was shot. 56,000 *****foot miles on this rig. Some light plowing. I was told the intercooler is prone to failure from twisting and could not be repaired, must be replaced. $1300. 00 later, I have lower power, lower gas milage, and the Old Part has a 1/4 puncture wound in it that looks as if it was inflicted by a punch... hmmm. Is a 1/4 inch hole enough to causea boost problem? Wouldn't that produce rich black smoke?

The other issue was warranty work... seems the fuel booster pump had an air leak and was starving the main pump... Wouldn't that produce white smoke (aka lean)? HELP! I am considering taking this up with the AG as it seems I got hoodwinked here.



I can provide additional info as requested. I am curious as to volume of turbo flow, normal turbo boost pressure, and just how big a hole would be needed to produce" no turbo boost".



I lost about 4 mpg as a result of the repair. Dropped from 15-16 mpg ave to 12-13 mpg.

 

[Firewalker]

Presure test your cooler and find the leak, if you can get to the leak have it brazed shut!!!!!! Easey fix. And yes any size hole in the cooler or intake tubes will affect the bost pressure for teh bad... ...





ken

 

[BillGotthelf]

I don't think that 1/4" hole would lose enough boost to produce more black smoke. I can't see white smoke either. I boost gauge would have made a difference. I can't believe it was the intercooler.

 

[NVR FNSH]

Aircraft heat exchangers are repaired on a daily basis.....



Based on 'twisting' the failure 'should be' a fatigue failure at a joint not a rupture. Which way is the edge on the 1/4" hole bent - in (meaning external damage) or out (meaning internal damage). A 1/4" hole will definitely reduce boost pressure but is it enough to cause zero boost? I doubt it. The dealer is full of it.



Brian

 

[ToolManTimTaylor]

Originally posted by Cjulius

I am curious as to volume of turbo flow, normal turbo boost pressure, and just how big a hole would be needed to produce" no turbo boost".

Glad to have ya here CJ!



Before I replaced my interconect hoses (Hump Hoses or whatever ya want to call 'em) I would blow em off DAILY to the point it was driving me nutz. (Stretched em with previous turbo) With a blown off hose I could muster 15 lbs 'o boost but would wipe out sunlight and exhaust temps would go thru the roof. Figure that is a 1 and a half inch gap or hole I was inflicting every time and I could still manage to make boost.



Your truck in stock configuration (Assuming it is stock and all) will produce 18-20 lbs of boost at heavy load.

 

[Cjulius]

The Damamge to the one tube is form external impact. The hole edges turn in. There is no damage to the grill of my truck. The truck NEVER produced black smoke and would produce white smoke intermittently. I feel the issue was the loose cap screws that hold the cover on the booster pump allowing air into the fuel stream... .

 

[Cjulius]

By the way folks, I am glad to be here. I am looking forwrd to an educational and entertaining exchange, all while learning more about my truck. I will be making some mods after the warrenty period on the engine expires(44,000 miles to go)... unless... what mods can I make now that do not violate waranty on the engine... . that's probably another topic... What I do need is a good Cummins Mechanic... not dealer associated, in the greater Plymouth area... I am willing to travel for good work... .