Frequently Asked Questions About Kenworth T800 Charge Air Coolers

What year models of Kenworth T800 trucks are these charge air coolers compatible with?

Our charge air coolers are designed to fit Kenworth T800 models from 1987 through 2007. However, compatibility can vary based on your specific engine configuration (CAT C15, Cummins ISX, Detroit Series 60, etc.). We recommend verifying your truck's VIN and engine model before ordering, as some mid-year production changes may affect fitment. Contact our support team with your truck's details for exact compatibility confirmation.

Are these charge air coolers made from aluminum or plastic tanks, and which is better for heavy-duty use?

We carry both aluminum tank and plastic tank charge air coolers. Aluminum tanks offer superior durability and heat dissipation, making them ideal for severe-duty applications and extreme temperature conditions. Plastic tank models are lighter weight and more cost-effective for standard highway use. Most owner-operators prefer aluminum for longevity, while fleet operators often choose plastic for initial cost savings. Both types feature aluminum cores for optimal cooling performance.

How difficult is the installation process, and what tools are required?

Installation typically takes 2-4 hours for experienced technicians. You'll need basic hand tools including socket sets, wrenches, and screwdrivers. The most challenging aspect is usually accessing and removing the old unit, which may require removing the grille and upper radiator hoses. Many customers report that having a second person helps significantly when maneuvering the cooler into position. Professional installation is recommended if you're unfamiliar with cooling system service, as improper installation can lead to boost leaks.

What are the common signs that my charge air cooler needs replacement?

Key indicators include loss of boost pressure (typically 2-5 PSI drop), increased exhaust temperatures, visible oil residue around cooler connections, reduced fuel economy, and black smoke during acceleration. Physical damage like bent fins, cracked tanks, or leaking connections are obvious replacement triggers. If you're experiencing intermittent power loss or your turbo seems to work harder than normal, pressure test your charge air cooler - anything over 3 PSI loss in 15 seconds indicates replacement is needed.

Do these aftermarket charge air coolers match OEM cooling performance?

Our charge air coolers meet or exceed OEM specifications for cooling efficiency and pressure drop. Most units feature upgraded core designs with increased fin density compared to original equipment, providing 5-10% better cooling capacity. Bar-and-plate construction models offer even greater durability and cooling performance than standard tube-and-fin OEM designs. All coolers are pressure tested to 30 PSI and include manufacturer warranties ranging from 1-3 years depending on the brand.