IK1201113 ­ 2010 MaxxForce 11 & 13 and 2013 N13 HT EGR Core Removal/Installation Page 1 of 14

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Title : 2010 MaxxForce 11 & 13 and 2013 N13 HT EGR Core Removal/Installation
Applies To : 2010 MaxxForce11/13, 2013 N13, All Truck Models

CHANGE LOG
2014/06/23 ­ Launch to field




DESCRIPTION
A faster, more effective procedure for High Temp (HT) Exhaust Gas Recirculation (EGR) Cooler repair has been
developed. This document will guide the user through the procedure of in chassis replacement of the cooler core for
a 2010 Emissions MaxxForce 11 or 13 or 2013 Emissions N13. The new procedure will REPLACE HT cooler
assembly replacement for INTERNAL leaks.
Please note, if the LT is being repaired with a High Temp (HT) replacement, reference iKNow 1201100 for LT core
replacement instructions.
It is important to thoroughly review the following instructions to prevent tool damage. A lot as been learned through
the development of the tool, and important notes/areas of concern are specifically called out at relevant points.

SYMPTOMS
Diagnostic Trouble Codes & Dashboard Indicator Lights:
DTC/Light

Description

SPN 111 FMI 1

Low Coolant

SPN 2659 FMI 21

EGR Low Flow
Malfunction Indicator Light (MIL)

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Red Stop Lamp (RSL)

Customer Observations or Concerns:
- Malfunction Indicator Light (MIL)
­ Red Stop Lamp (RSL)
­ Coolant consumption
- Low coolant
- Coolant puddling under engine
­ White smoke from the exhaust
- Coolant in the oil or oil analysis

SPECIAL TOOLS
Tool Description

Tool Number

LT Core Replacement Tool

12­892­04

HT Core Replacement Tool

12­892­05

Coolant Management Tool

KL5007NAV

EGR Leak Detection Kit

12­892­02

Comments

Instructions
Link
Link

Only if necessary

Link

DIAGNOSTIC STEPS
All diagnostic steps should be completed through the Fault Code Action Plans for 111-1 or Coolant
Consumption/Loss. At this point, the truck should have been diagnosed with an internal leak of the HT cooler.
REPAIR NOTES:
-The following procedure should NOT BE USED if the cooler is LEAKING EXTERNALLY for cracks, porosity,
broken fittings, etc. Instead, replace the entire HT cooler assembly.
-If the cooler is leaking at the joint between the HT and the center plate, replace the HT assembly.
-If leaking between the center plate and the LT assembly, reference the LT seal kit in the parts section.
­If leaking from the LT Y­Fitting (only if the fitting is bolt­on), reference the LT Y­Fitting kit.

TESTING NOTE
If BOTH cooler halves are found leaking, make sure the LT cooler did not appear failed due to residual air in the
core from the High Temp testing. Typically this happens when the leak detection hose is not vented to atmosphere
(left in water) between tests and/or when the HT is tested and the fittings are switched quickly--the air pressure in
the core passages is still enough to cause bubbles when putting pressure to the LT.

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Figure 1: 2010 MaxxForce 11/13 EGR Cooler Assembly
Item 1: High Temp (HT) Cooler
Item 2: Low Temp (LT) Cooler
Item 3: LT Cooler Pressure Test Port (dearation fitting)
Item 4: HT Cooler Pressure Test Port (dearation fitting)

SERVICE PARTS INFORMATION
Quantity
Notes
Required

Kit Description

Part Number

Kit, High Temp Core

2513445C91

1

Required

Kit, Low Temp Core

2513209C91

1

ONLY if necessary

Module, HT

3014254C95

1

ONLY if necessary

Module, LT (MaxxForce)

3015862C92

1

For external leaks ONLY, in place of LT Kit

Module, LT (N13)

5010689R91

1

For external leaks ONLY, in place of LT Kit

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Kit, Low Temp Seal

1

Kit, Y­Fitting (Low Temp)

1844447C1

P­80 Assembly Lube

2511097C1

For external leaks between the LT and the plate
For leaks at LT Y-Fitting (bolt-on ONLY)

1

Case of 6 Pints

'

REPAIR STEPS
The following repair steps are for the cooler removal and installation in chassis.

WARNING
To prevent personal injury or death, read all safety instructions in the "Safety Information" section of the diagnostic
manual, linked here.

WARNING
To prevent personal injury or death, shift transmission to park or neutral, set parking brake, and block wheels
before doing diagnostic or service procedures.

WARNING
To prevent personal injury or death, make sure the engine has cooled before removing components.

WARNING
To prevent personal injury or death, do not let engine fluids stay on your skin. Clean skin and nails using hand
cleaner and wash with soap and water. Wash or discard clothing and rags contaminated with engine fluids.

REMOVAL PROCEDURE:
The dog house, coolant crossover and EGR tubes should have already been removed to gain access to the cooler
for pressure testing.
1.

Remove and discard the 9 bolts securing the EGR Valve to the HT cooler housing.

2.

Remove the two dowel pins in the top right and bottom left corner of the housing.

3.

Discard the EGR valve to cooler gasket.

4.

Install the removal tool

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Figure 2: HT Core Removal Tool
Item 1: Removal plate
Item 2: Support rods
Item 3: Forcing screw
Item 4: Thumb screws
a. Screw in the support rods in the two upper right, and lower, bottom left corner, holes (Figure 2, Item 2).
Tighten using a 9mm open-end wrench.
WARNING
It is critical that the rods get torqued to the housing. There is a bevel between the threads and the shaft, designed specifically to drive
the cooler header onto the shaft. Failure to do so will lead to the header being caught on the rod and breaking/bending the rod. There
have been instances of the housing being damaged to the point of replacement, as well.

b. Slide the puller over the rods
c. Attach/tighten the thumb screws (Figure 2, Item 4).

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Figure 3: HT Core Tool Plate with Screws

d. Lastly screw the removal plate into the core using the eight screws supplied in the HT kit (Figure 3).
Reference the HT Tool Instructions (12­892­5, TL2900093) for more information.

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Figure 4: High Temp Core and Spring Clips
Item 1: HT Cooler Core
Item 2: Spring Clips

5.

Back out the bolt to extract the core from the housing (counter­clockwise).

There are two pairs of spring clips supporting the core in the housing. Therefore, the core will need to be pulled
about 16 inches before it will be free to remove.
6.

Unscrew the knobs from the rods.

7.

Remove the cooler core from the housing.

8.