Leaking Charge Air Cooler Running Costs

With the average cost of diesel fuel in the USA at $3.68 per gallon1, a leaking charge air cooler is costing truck owners a serious amount of money in wasted fuel.

According to the Federal Highway Administration, a long-haul truck driver in the United States typically drives over 100,000 miles per year.

The average fuel economy for Class 7 and Class 8 trucks in the United States and Canada is around 5.49 miles per gallon (MPG)2.

Dura-Lite™ has produced a useful “Leaking Charge Air Cooler Calculator” that you can use to discover how much you can save by replacing a leaking CAC with a replacement Dura-Lite Evolution® Charge Air Cooler.

Using our calculator, Fuel cost of $3.68 USD gal, Fuel economy of 5.49 MPG, and an average daily trip of 550 miles, we calculate that you could be saving $25 per day! That’s $6,500 USD per year and for a fleet of 25 vehicles, it could be robbing you of $162,500 in wasted fuel every year! Leaks are sneaks!

Compare the difference:

Discover what a leaking charge air cooler could be costing you.

  Leaking charge air cooler Dura-Lite™ leak-free charge air cooler
Fuel cost $3.68 $3.68
Fuel economy 5.5 5.9
Average trip per day 550 550
Consumption per day 100.0 Gal 93.2 Gal
Cost per day $368.00 $343.05

Dura-Lite™ could save you per vehicle:

Savings per day* $25
Savings per week* $125
Savings every 4 weeks* $500
Savings per year* $6,500

Dura-Lite™ could save fleets:

Number of vehicles: 25 50 75 100
Savings per day* $625 $1,250 $1,875 $2,500
Savings per week* $3,125 $6,250 $9,375 $12,500
Savings per 4 weeks* $12,500 $25,000 $37,500 $50,000
Savings per year* $162,500 $325,000 $487,500 $650,000

*An engine with a leaking Charge Air Cooler will waste fuel. Dura-Lite’s calculation of the amount of fuel your engine is wasting is approximately what is shown above. The calculations are only approximate amounts based on a formula, using information from customer experiences with our products. Those experiences may be different from yours. The amount you save may be more or less than what is shown, due to other factors not reflected in the calculations. Dura-Lite™ does not warrant the accuracy of the calculations.

Enter the numbers from your own experience into our calculator to see what you could be saving every year:

View Calculator

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