Frequently Asked Questions About Kenworth T680 Charge Air Coolers

Will this charge air cooler fit my specific Kenworth T680 model year and engine configuration?

Kenworth T680 charge air coolers vary by model year (2013-present) and engine type. Most units fit 2013-2022 models with Paccar MX-13, Cummins ISX15, or Cummins X15 engines. However, differences exist between early models (2013-2016) and newer ones (2017+) due to updated mounting brackets and inlet/outlet configurations. Always verify your VIN, engine serial number, and existing cooler part number before ordering. If you're unsure, our team can help match the correct cooler using your truck's specifications.

What are the most common installation challenges when replacing a T680 charge air cooler?

The primary installation challenges include: limited access space requiring removal of the grille and sometimes the bumper, proper alignment of mounting brackets (especially on 2017+ models with revised mounting points), and ensuring correct hose routing to prevent kinking. Most installations take 2-4 hours for experienced mechanics. Critical tips: Have new clamps ready as reusing old ones often leads to leaks, check for bent or damaged mounting tabs before installation, and ensure the cooler fins aren't damaged during handling. Some aftermarket coolers may require minor bracket modifications.

How do aluminum and plastic tank charge air coolers compare in terms of durability and performance?

All-aluminum charge air coolers typically outlast plastic tank versions by 2-3 years in heavy-duty applications. Aluminum tanks resist cracking from thermal cycling and pressure spikes better than plastic, which can develop stress cracks around the inlet/outlet connections after 150,000-200,000 miles. However, quality plastic tank coolers from OEM suppliers perform adequately for most highway applications and cost 20-30% less. For severe-duty use, vocational trucks, or high-boost applications, aluminum construction is worth the investment.

What are the warning signs that my T680's charge air cooler needs replacement?

Key indicators include: loss of boost pressure (check with a boost gauge - anything over 3-4 PSI loss indicates a problem), visible oil residue around cooler connections, increased fuel consumption (typically 0.5-1 MPG drop), higher exhaust gas temperatures, and the engine derating or throwing boost-related fault codes. Physical inspection may reveal bent fins reducing airflow by 30% or more, cracks in plastic end tanks, or corrosion at the core-to-tank joints. Don't wait for complete failure - a leaking cooler can damage your turbo and reduce engine life.

Are aftermarket charge air coolers as reliable as OEM Kenworth parts?

Quality aftermarket coolers from established manufacturers often match or exceed OEM performance at 40-60% lower cost. Look for coolers that meet or exceed OEM pressure ratings (typically 50-60 PSI working pressure), use the same core construction (bar-and-plate or tube-and-fin), and include proper mounting hardware. Reputable aftermarket brands offer 2-year warranties comparable to OEM coverage. Avoid ultra-cheap imports that use thinner materials or skip quality testing. The key differences are usually in fit tolerance - some aftermarket units may require minor bracket adjustments during installation.