[Jerryrig]

Hello, I have a 2008 Newell and the CAC is leaking.  The original manufacturer was Positech International, but they seem to now be out of business.  Does anyone know of a company that can build a replacement?  I would prefer not to rebuild the one I have if possible due to it being 23 years old, possibly.  It may have been changed out in the past before I owned the coach.  The CAC has been painted black and it looks like a bomber can job and not a factory job.  

Also if anyone has a drawing of the unit that would allow another manufacturer or shop to build one, that would be exceptional!

I have a couple of photos of the leaking around the frame supporting the CAC.  Seems the pressure has blown out the sealant that was used when it was installed.  The area must be somewhat confined to be able to build pressure.  Sorry, I tried to upload a video, but system doesn't allow it.

Any advice is certainly appreciated!

   
   
   

Thank you,

Jerry Hayes

[Jack Houpe]

I can almost bet you'll find someone in the performance world that can build you one but I would remove that one and have someone with tig welding experience weld it back up.

[Little]

in your area there will be a lot of fabricators that can handle both repair and manufacture of new unit. The fellow that helps me out was in a motorcycle wreck in May and is out of commission right now. Perhaps Tom knows of someone from his side of town. The shop at 'All Aboard America' nay have their favourite fabrication shop. I too would try to get it 'tigged' up. Good luck.

[[email protected]]

My CAC is coming out and I am putting a A2W system in its place. A regular car radiator will go where the CAC is located and a air to water intercooler will go in the air stream between the turbo and the intake. There are several test rigs set up in friends coaches and the results are very promising.

[Jerryrig]

I can almost bet you'll find someone in the performance world that can build you one but I would remove that one and have someone with tig welding experience weld it back up.

Hi Jack, 

When I finally got the CAC out the inlet header side was cracked from the bottom to the top and actually over the top.  Due to how Newell mounts the CAC, the labor to remove and install was fairly significant.  It took about 12 hours total to remove and replace CAC.  I went ahead and installed a new CAC to avoid doing this again in the near term.  

There was a Prevost in the shop and they also removed and replaced the CAC on it and did it in 5 hours.  Seems theirs are a bit easier to swap out.

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in your area there will be a lot of fabricators that can handle both repair and manufacture of new unit. The fellow that helps me out was in a motorcycle wreck in May and is out of commission right now. Perhaps Tom knows of someone from his side of town. The shop at 'All Aboard America' nay have their favourite fabrication shop. I too would try to get it 'tigged' up. Good luck.

Hi Mark,

I did some checking around to try and find a "better" replacement. I tried to work with DuraLite but to no avail.  They did not have any interest to build one with their high temperature silicone grommet from the fin to header.  I had Leo at All Aboard America do all the work (replaced with a new CAC from Newell) and I think he may have said a few bad words about how the CAC is mounted and the effort to get it in and out.  He really does great work!

[Jerryrig]

My CAC is coming out and I am putting a A2W system in its place. A regular car radiator will go where the CAC is located and a air to water intercooler will go in the air stream between the turbo and the intake. There are several test rigs set up in friends coaches and the results are very promising.

Hi Jeff,

I would love to hear more about this as you move forward!  I like the idea but the A2W heat exchanger has to be a truly rock solid design to prevent any chance of having a leak from the water side get into the air side.  I would love to see a P&ID for the system!

[PiperP2000]

Jerry- I just replaced our CAC on 1241.  There was nothing easy about the removal and installation.  Hopefully that’s a once every 15 year job.  One word of caution is should you choose to replace the CAC flexible couplings/boots you must use heavy duty 4 ply boots.  The off the shelf ones from someone like Freightliner don’t cut it.  They aren’t up to the task of handling the 60 psi of boost the C-15 makes.  I had the forward most boot blow off on my initial test drive (the one in the worst location).  I ended up replacing all boots and clamps with a Big Boss set from PDI.  PDI wasn’t the least bit surprised when I called and explained the issue I was having.

[Jerryrig]

I agree the thinner ply turbo boots are too thin. Here is a link to the ones I got from Amazon as the ones from local dealer where way to thin. Working temperature: -65F ~ 500F degrees；Working Pressure: 0.3 to 0.9Mpa；Bursting Pressure: 245 PSI. This indicates a MAWP of about 130 PSI which seems high, but if you use a SF of 4, that would be about 60 PSI, which is what we want.
https://www.amazon.com/dp/B0F98W8HYY?ref...tle_1&th=1

Here are the clamps I also had to buy as the new turbo boots are thicker than the original and needed a larger diameter clamp;
https://www.amazon.com/dp/B0002QTJRM?ref...in_title_1