Frequently Asked Questions About Mack RD Truck Charge Air Coolers

What years and models of Mack RD trucks are these charge air coolers compatible with?

Our charge air coolers are designed to fit Mack RD600, RD688, and RD690 models from 1990 through 2004. The most common applications are for trucks with Mack E7 and E-Tech engines. Always verify your specific engine model and serial number before ordering, as some mid-year production changes may affect fitment. We recommend checking your existing cooler's part number or dimensions if you're unsure about compatibility.

Are these charge air coolers made from aluminum or plastic tanks, and which is better for my application?

We offer both aluminum tank and plastic tank options. Aluminum tanks are typically more durable and handle higher boost pressures better, making them ideal for heavy-duty applications or modified engines. Plastic tank coolers are lighter weight and often more cost-effective for standard applications. Both types feature aluminum cores. For trucks running stock boost levels under 35 PSI, plastic tanks perform well. For higher boost applications or extreme duty cycles, we recommend aluminum tanks.

What are the most common installation challenges, and do I need special tools?

Installation typically takes 2-4 hours depending on your experience level. The main challenges include removing the old cooler without damaging surrounding components and properly aligning the new unit. You'll need basic hand tools, plus hose clamp pliers and possibly a trim removal tool for tight spaces. Common issues include seized mounting bolts and degraded rubber hoses that may need replacement. We recommend having new clamps and coolant on hand. Some models require removing the grille or loosening the radiator for clearance.

How do I know if my charge air cooler is failing, and should I replace hoses at the same time?

Signs of failure include loss of boost pressure, excessive black smoke, decreased fuel economy, and oil residue in the intake system. You can pressure test your cooler at 30-35 PSI to check for leaks. We strongly recommend replacing all charge air hoses and clamps during cooler replacement, as old hoses often develop internal delamination that isn't visible externally. This prevents comeback issues and ensures optimal performance. Budget an extra $150-300 for quality silicone hoses and constant torque clamps.

What's the difference between OEM-style and aftermarket performance charge air coolers?

OEM-style coolers match factory specifications and mounting points exactly, typically featuring 2-inch core thickness and standard tube-and-fin construction. Performance aftermarket options often have thicker cores (2.5-3 inches), bar-and-plate construction, and increased cooling capacity. Performance coolers can reduce intake temperatures by an additional 20-40 degrees but may require minor bracket modifications. For stock engines, OEM-style works perfectly. For tuned engines or heavy towing applications, performance coolers provide better heat rejection and durability.