Frequently Asked Questions About Ford Aeromax Truck Charge Air Coolers

What years and models of Ford Aeromax trucks are these charge air coolers compatible with?

Our charge air coolers are designed to fit Ford Aeromax trucks from 1988 to 1997, including both the L9000 and LTL9000 series. Each product listing specifies exact model compatibility, but most units work with Caterpillar 3406, Cummins N14, and Detroit Series 60 engines. Always verify your engine model and serial number before ordering, as some mid-year production changes may affect fitment.

How difficult is it to install a replacement charge air cooler, and what tools do I need?

Installation typically takes 3-4 hours for experienced mechanics and requires basic hand tools including socket sets, wrenches, and hose clamp pliers. You'll need to drain the coolant system, remove the grille and possibly the bumper for access. The most challenging part is usually disconnecting the old rubber couplings and aligning the new unit properly. We recommend having new clamps and couplings on hand, as the originals often need replacement during installation.

What's the difference between aluminum and plastic tank charge air coolers, and which is better?

Aluminum tank coolers offer superior durability and heat dissipation, lasting 8-10 years on average versus 4-6 years for plastic tanks. Plastic tanks are lighter and less expensive initially but are prone to cracking from thermal cycling and vibration. For heavy-duty applications or trucks operating in extreme temperatures, aluminum tanks are worth the extra investment. Both types use aluminum cores, so cooling efficiency is similar when new.

How can I tell if my charge air cooler is failing before it completely breaks down?

Watch for these warning signs: loss of power under load, black smoke from the exhaust, higher than normal intake air temperatures (above 150?F), oil residue in the intercooler pipes, or visible coolant leaks around the tank seams. A pressure test at 30 PSI can reveal small leaks before they become major failures. If boost pressure drops more than 2-3 PSI from turbo to intake manifold, the cooler likely needs replacement.

Are aftermarket charge air coolers as good as OEM units for Ford Aeromax trucks?

Quality aftermarket coolers from reputable manufacturers often match or exceed OEM specifications at a lower price point. Look for units with at least 2-row cores, welded aluminum construction, and pressure ratings of 45 PSI or higher. Many aftermarket options feature improved fin density and updated tank designs that address common OEM failure points. Always verify the warranty coverage - reputable aftermarket coolers typically include 1-2 year warranties.