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FAQs

Can’t find the answer you’re looking for? We’ve compiled some of our most frequently asked questions to help you out.

How can I find my local Distributor/ Dealer on your Website?

Dura-Lite is a Customer Service driven company and we want to take every opportunity we can to talk to and help out our customers. We feel by having customers contact Dura-Lite Customer Support at 800-661-1117 we can serve them more effectively. We will not only offer information on the nearest Distributor/Dealer, but will also help to source the product you are looking for.

How do I contact Dura-Lite?

You can contact us at:
Address: 12012-44th St. S.E.
Calgary, Alberta T2Z 4A2
Canada
Tel: 403-259-2691
Toll Free: 800-661-1117
Fax: 403-252-2784
E-Mail: inquiry@duralite.net

Where are Dura-Lite Charge Air Coolers manufactured?

Dura-Lite has manufacturing facilities in North America, Australia, and Asia. The origin of a specific part can vary from time to time, dependent on demand and plant capacity. All production, regardless of the plant location, is built to Dura-Lite’s specifications with Dura-Lite production staff.

Does Dura-Lite meet the Original Equipment manufacturers specifications?

Yes. Dura-Lite’s products meet or exceed Original Equipment performance specifications.

How does the performance of a Dura-Lite Charge Air Cooler compare to the Original Equipment Charge Air Cooler?

Dura-Lite Evolution Charge Air Coolers meet or exceed the Original Equipment performance specifications.

What applications does Dura-Lite manufacture Charge Air Coolers for?

Dura-Lite currently manufactures hundreds of different Charge Air Coolers for turbo-diesel powered equipment including (but not limited to) the following applications; Agricultural, Bus, Cement Mixers, Classes 2, 3, 4, 5, 6, 7, and 8 Trucks, Coach, Construction, Fire Trucks, Generators and Power Units, Government, Marine, Military, Motorhome, Off-Highway Vehicles, Oil Field, On-Highway Vehicles, Recreational, Refuse, Stationary, Transit, Vocational, and many others. Contact Dura-Lite Customer Support at 800-661-1117 if you are unable to find a Charge Air Cooler or Radiator Part # for your application.

Can a leaking Original Equipment Charge Air Cooler be repaired?

No. Repairing a leaking Original Equipment style Charge Air Cooler is nothing more than a band-aid and it will end up costing you more in down time when it leaks again. If the original design wouldn’t last, how can a patch repair be expected to? The cost of a new Charge Air Cooler will ultimately be far less than the loss of fuel economy you will experience as the cooler leaks more each day. You also risk a potential turbo charger replacement as the turbo continues to work harder to compensate for a leaking Charge Air Cooler. In addition there is the potential for engine wear, and other issues associated with a leaking Charge Air Cooler.

Is Dura-Lite the only grommeted Charge Air Cooler available?

No. Although there have been attempts to copy Dura-Lite’s design, Dura-Lite is the original inventor. Dura-Lite’s proven technology allows it to offer an industry leading (non-prorated) 7 Year/ 1,000,000 Mile Warranty on most Part #’s. Dura-Lite’s design and manufacturing process are protected under numerous patents. Companies offering imitation products are infringing on Dura-Lite’s patents and could be subject to legal action.

What is a grommet?

Dura-Lite refers to the seal between the tube-to-header joint as a grommet. The grommet allows the tubes to expand and contract in the grommet/ header, which eliminates the typical tube-to-header failure mode and resulting leakage.

Does the rubber seal leak?

No. The seal actually isn’t rubber, Dura-Lite uses a specially formulated high heat Patented Silicone Grommet Tube-To-Header Seal System. The silicone grommet allows the tubes to expand and contract in the grommet/ header, which eliminates the typical tube-to-header failure mode and resulting leakage. All Dura-Lite Charge Air Coolers are manufactured 100% leak free.

Can the grommets be replaced?

Yes, but only at Dura-Lite’s manufacturing facility. However, there should be no need to replace the grommets, as they are designed to last for the life of the Charge Air Cooler.

Where can I get a Dura-Lite logo?

Please contact Dura-Lite Customer Support at 800-661-1117.

What is a Round Tube Charge Air Cooler?

Round Tube is a trademark that Dura-Lite Heat Transfer Products Ltd. (“Dura-Lite”) uses for its 1st Generation Charge Air Coolers.

What is a New Generation Charge Air Cooler?

New Generation is a trademark that Dura-Lite Heat Transfer Products Ltd. (“Dura-Lite”) uses for its 2nd Generation Charge Air Coolers.

What is an Ultimate Solution Charge Air Cooler?

Ultimate Solution is a trademark that Dura-Lite Heat Transfer Products Ltd. (“Dura-Lite”) uses for its 3rd Generation on-highway Charge Air Coolers.

What is an Evolution Charge Air Cooler?

Evolution is a registered trademark that Dura-Lite Heat Transfer Products Ltd. (“Dura-Lite”) uses for its 4th Generation on-highway Charge Air Coolers. Where applicable, Dura-Lite Evolution Charge Air Coolers have the Dura-Lite Part # prefix “US”.

What is a Channel Flow Charge Air Cooler?

Channel Flow is a trademark that Dura-Lite Heat Transfer Products Ltd. (“Dura-Lite”) uses for its agricultural and industrial Charge Air Cooler applications. Where applicable, Dura-Lite Channel Flow Charge Air Coolers have the Dura-Lite Part # prefix “AG”.

For all Dura-Lite warranty related questions please visit our Warranty page.

View Warranty Details

If there is a turbo failure, can a Charge Air Cooler be cleaned and re-used?

No. A Charge Air Cooler should not be cleaned or re-used following a turbo failure. The Charge Air Cooler is often damaged by the event, and may cause further problems if re-used.

Can a Dura-Lite Charge Air Cooler that has been contaminated with oil, be cleaned and re-used?

No. A Dura-Lite Charge Air Cooler cannot be cleaned or re-used once it has been contaminated with oil.

How often should a Charge Air Cooler be tested?

Dura-Lite recommends that a Charge Air Cooler should be tested every time the vehicle is in for service and/ or when the oil is changed. It is vital to the performance and reliability of the engine that leaks are detected as soon as possible in order to reduce problems caused by a leaking Charge Air Cooler.

What percentage of Charge Air Coolers are leaking?

Dura-Lite estimates 40% of trucks 2 (two) years or older, have Charge Air Coolers that are leaking out of the engine manufacturers specifications.

How do you test a Charge Air Cooler to determine if it is leaking?

Dura-Lite manufactures a Test Kit that includes all the tools and instruction necessary to test most makes, models, and/ or sizes of Charge Air Coolers safely and accurately. Please reference Dura-Lite’s Charge Air Cooler Tester page for additional information on the basic Tester-Kit procedure. Dura-Lite’s Part # Tester-Kit is available through Dura-Lite Distributors/ Dealers. Please contact Dura-Lite Customer Support at 800-661-1117 for information on a Distributor/ Dealer near you.

Can I test my Charge Air Cooler myself?

Yes. Dura-Lite manufactures a Test Kit that includes all the tools and instruction necessary to test most makes, models, and/ or sizes of Charge Air Coolers safely and accurately. Please also reference Dura-Lite’s Charge Air Cooler Tester page for additional information on the basic Tester-Kit procedure. Dura-Lite’s Part # Tester-Kit is available through Dura-Lite Distributors/ Dealers. Please contact Dura-Lite Customer Support at 800-661-1117 for information on a Distributor/ Dealer near you.

What are the symptoms of a non-performing or leaking out of specification Charge Air Cooler?

A leaking Charge Air Cooler results in incomplete combustion which causes; loss of engine power, increased fuel consumption, elevated soot levels in the oil, premature piston, ring, and valve failure, turbocharger failures, elevated coolant temperatures, and exhaust manifold failure.

Is there a testing guideline to follow to determine if a Charge Air Cooler is leaking out of specification?

Yes. The rule of thumb is to pressure the Charge Air Cooler up to 30 psig and that it should hold air for at least 15 seconds. If there is a pressure loss of 5 psig or more within the 15 seconds, the Charge Air Cooler is leaking out of specification (Leak Down Rate Specification) and it should be replaced immediately. This is only a guideline and it is very important to check the engine manufacturers Leak Down Rate Specification (some common specifications are noted below). Please also reference Dura-Lite’s Charge Air Cooler Tester page for additional information on the basic Tester-Kit procedure.

Leak Down Rate Specifications:
Caterpillar 5 psig in 15 seconds @ 30 psig
Cummins (ISB, ISC, N14) 7 psig in 15 seconds @ 30 psig
Cummins (ISX, M11)  5 psig in 15 seconds @ 30 psig
Detroit Diesel 5 psig in 30 seconds @ 30 psig
International 5 psig in 15 seconds @ 30 psig
Mack 5 psig in 15 seconds @ 30 psig
Mercedes 5 psig in 15 seconds @ 25 psig
Volvo 5 psig in 15 seconds @ 30 psig

* psig (pound-force per square inch gauge)


What could a Leaking Charge Air Cooler cost the operator?

An engine with a leaking Charge Air Cooler will waste fuel. Dura-Lite’s calculation of the amount of fuel an engine is wasting as a result of a Leaking Charge Air Cooler is approximately what is shown in the table below (based on a fuel cost of $ 2.25 per gallon).

Leaking Charge Air Cooler Cost:
Fuel Cost Calculator: Leaking 
Charge Air Cooler:
Dura-Lite 
Leak Free 
Charge Air Cooler:
   
Fuel Cost $2.25 $2.25 Per Gallon US Gallons
Fuel Economy 5.5 5.9 MPG (Estimate)  
Average Trip Per Day 600 600 Miles   
Consumption Per Day 109.1 101.7 Gallons US Gallons
Cost Per Day $245.45 $228.81     *   

* 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.

Please reference Dura-Lite’s Leaking CAC Calculator to find out what you can save!

What could a Dura-Lite Leak Free Charge Air Cooler save the operator?

Dura-Lite’s calculation of the amount of fuel an engine is wasting as a result of a Leaking Charge Air Cooler and an operator could save with a Dura-Lite Leak Free Charge Air Cooler is approximately what is shown in the table below (based on a fuel cost of $ 2.25 per gallon).

Dura-Lite Could Save An Operator:
Per Day* $17.00
Per Week* $85.00
Every 4 Weeks* $340.00
Per Year* $4,420.00

* 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.

Please reference Dura-Lite’s Leaking CAC Calculator to find out what you can save!

What could a Dura-Lite Leak Free Charge Air Cooler save a fleet?

An engine with a leaking Charge Air Cooler will waste fuel. Dura-Lite’s calculation of the amount of fuel an engine is wasting is approximately what is shown in the table below (based on a fuel cost of $ 2.25 per gallon).

Dura-Lite Could Save A Fleet:
Number Of Vehicles: 50 100 250 500 750 1,000
Per Day* $17.00 $850.00 $1,700.00 $4,250.00 $8,500.00 $12,750.00 $17,000.00
Per Week* $85.00 $4,250.00 $8,500.00 $21,250.00 $42,500.00 $63,750.00 $85,000.00
Every 4 Weeks* $340.00 $17,000.00 $34,000.00 $85,000.00 $170,000.00 $255,000.00 $340,000.00
Per Year* $4,420.00 $221,000.00 $442,000.00 $1,105,000.00 $2,210,000.00 $3,315,000.00 $4,420,000.00

* 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.

Please reference Dura-Lite’s Leaking CAC Calculator to find out what you can save!

What applications does Dura-Lite manufacture Charge Air Coolers for?

Dura-Lite currently manufactures hundreds of different Charge Air Coolers for turbo-diesel powered equipment including (but not limited to) the following applications; Agricultural, Bus, Cement Mixers, Classes 2, 3, 4, 5, 6, 7, and 8 Trucks, Coach, Construction, Fire Trucks, Generators and Power Units, Government, Marine, Military, Motorhome, Off-Highway Vehicles, Oil Field, On-Highway Vehicles, Recreational, Refuse, Stationary, Transit, Vocational, and many others. Contact Dura-Lite Customer Support at 800-661-1117 if you are unable to find a Charge Air Cooler or Radiator Part # for your application.

How do you determine which Dura-Lite Charge Air Cooler fits a vehicle?

Determine the Original Equipment Part # of the Charge Air Cooler on the vehicle. Distributor/ Dealers can then cross the Part # to a Dura-Lite Part # on Dura-Lite’s website Product Catalog or contact Dura-Lite Customer Support at 800-661-1117 for further assistance.

How do you determine the Original Equipment Part # of a Charge Air Cooler on a vehicle?

Open the hood or engine compartment of the vehicle and look for the Original Equipment Part # Label on the Charge Air Cooler. The Label is typically located on the top center of the Charge Air Cooler. If there isn’t a Label present, call your Dealer. Provide the vehicles V.I.N. to the Dealer and request the Original Equipment Charge Air Cooler Part #.

Is Dura-Lite available as an Option on a new vehicle?

With the exception of some specialty Original Equipment applications, Dura-Lite is not available as an Original Equipment option at this time. However, the vehicle owner can specify that the Dealer install a Dura-Lite Charge Air Cooler on the vehicle, prior to delivery.

Can I purchase directly from Dura-Lite?

Dura-Lite sells its products through extensive distribution channels of Distributors/ Dealers. Please contact Dura-Lite Customer Support at 800-661-1117 for information on a Distributor/ Dealer near you.

How much does a Dura-Lite Charge Air Cooler cost?

Dura-Lite sells its products through extensive distribution channels of Distributors/ Dealers who will provide your product cost. Please contact Dura-Lite Customer Support at 800-661-1117 for information.

How can I find my local Distributor/ Dealer on your Website?

Dura-Lite is a Customer Service driven company and we want to take every opportunity we can to talk to and help out our customers. We feel by having customers contact Dura-Lite Customer Support at 800-661-1117 we can serve them more effectively. We will not only offer information on the nearest Distributor/ Dealer, but will also help to source the product you are looking for.

Is a Dura-Lite Charge Air Cooler more expensive than an Original Equipment Charge Air Cooler?

The price of Original Equipment Charge Air Coolers varies widely. Dura-Lite Charge Air Coolers are very competitively priced vs. the Original Equipment. Dura-Lite’s value is beyond the price and we offer an incomparable (non-prorated) 7 Year / 1,000,000 Mile Warranty on most Charge Air Cooler Part #’s. The warranty is covered across North America.

How long after a Dura-Lite product is ordered does it take to ship?

Dura-Lite products are available through extensive distribution channels of Distributors/ Dealers. Please contact Dura-Lite Customer Support at 800-661-1117 for information. Orders received by 2:00 PM MST (Mountain Standard Time) for products in stock will be shipped the same day.

Can Dura-Lite products be shipped for same day next day delivery?

Yes. Dura-Lite products are available through extensive distribution channels of Distributors/ Dealers. Same day and Next day service is available for most Charge Air Coolers and Radiators in North America. Please contact Dura-Lite Customer Support at 800-661-1117 for additional information.

What Charge Air Cooler Part #’s does Dura-Lite manufacture?

Dura-Lite currently manufactures hundreds of different Charge Air Coolers and we have an extensive inventory to support our product offering. Contact Dura-Lite Customer Support at 800-661-1117 if you are unable to find a Charge Air Cooler or Radiator Part # for your application.

What if I want a Charge Air Cooler for a custom application?

Contact Dura-Lite Customer Support at 800-661-1117 if you are unable to find a Charge Air Cooler or Radiator Part # for your application.

Where can I purchase a Tester-Kit?

Dura-Lite sells its Part # Tester-Kit and other products through extensive distribution channels of Distributors/ Dealers. Please contact Dura-Lite Customer Support at 800-661-1117 for information.

Why is a Dura-Lite Charge Air Cooler considered to be a premium product?

Dura-Lite’s offers an incomparable (non-prorated) 7 Year / 1,000,000 Mile Warranty on most Evolution Charge Air Cooler Part #’s. The warranty is covered across North America. Dura-Lite has a proven track record with more than 28-years of experience in the heat transfer business. Dura-Lite’s Evolution Charge Air Coolers lead the industry in both quality and durability, which allows them to outlast any other Charge Air Coolers in the marketplace today.

Why should I buy a Dura-Lite Charge Air Cooler vs. repairing my leaking Original Equipment Charge Air Cooler?

It’s not possible to successfully repair a tube-to-header leak on a Charge Air Cooler and any repair made would simply be a temporary fix. At $2.25 per gallon, a leak-free Dura-Lite Evolution Charge Air Cooler could save you $4,420.00 or more per year. Dura-Lite Evolution Charge Air Coolers have a (non-prorated) 7 Year / 1,000,000 Mile Warranty on most Part #’s and the warranty is covered across North America.

I have seen other companies offer 10-yr and lifetime warranties. Are these companies Charge Air Coolers better than Dura-Lite’s?

Dura-Lite manufactures the best Charge Air Coolers in the world, backed by the best warranty in the business with North American coverage. Other companies may advertise a longer warranty period, but the warranties are typically prorated with exceptions, exclusions and do not have North American coverage to support the product.

Why should I purchase a Dura-Lite Charge Air Cooler?
  • All-Makes product coverage with hundreds of Part #’s for any diesel application. Additional Part #’s added continually.
  • Dura-Lite offers the best warranty in the business (non-prorated) 7 Year/ 1,000,000 Mile Warranty on our Evolution Charge Air Cooler.
  • Less than 1% failure rate.
  • North America Warranty Coverage.
  • Warranty backed by the factory.
  • No costly downtime.
  • Reduced overall fuel costs. A non-performing Charge Air Cooler will cost more in fuel. At $2.25 per gallon, a leak-free Dura-Lite Evolution Charge Air Cooler could save you $4,420.00 or more per year.

Learn more about our Charge Air Coolers

Why should I purchase a Dura-Lite Radiator?
  • Stronger fiber-reinforced tanks.
  • Heavier stronger headers for unsurpassed durability.
  • Extra header-stiffening plate helps ensure our radiators remain durable and last for longer.
  • Replacements for most applications.
  • Serving the heavy duty truck, transit bus, motorcoach, motorhome, industrial, agricultural, and construction markets.

Learn more about our truck radiators

How do initiate a return with Dura-Lite?

Please contact Dura-Lite Customer Support at 800-661-1117 to obtain an RGA (Returned Goods Authorization). A return will not be accepted by Dura-Lite without an RGA.

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We offer a large selection of charge air cooler and radiator solutions to meet your performance and durability needs.

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