IK1201113 ­ 2010 MaxxForce 11 & 13 and 2013 N13 HT EGR Core Removal/Installation Page 1 of 12

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10/2/2014
Aaron
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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
2014/10/02 ­ Revised note about not using impact on tool, added note about DOC coolant conamination (end of repair procedure­­never bake),
added another note in diagnostics section, about half cooler replacement being necessary in some cases, added comment about damaged core
during shipping in parts section, and revised comment about tightening down the support rods, in "Removal" section.
2014/09/12 ­ Revised instructions on vacuum filling. Minor grammar changes. Removed Notice for mis­built kits (all should be fixed now)
2014/07/22 Added link/instructions to repair video in LMS ("Repair Procedure")

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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 (ex; never use an impact to remove/install the core).

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)

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

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SPECIAL TOOLS
Tool Description

Tool Number

LT Core Replacement Tool

12­892­04

Comments

Instructions
Link

HT Core Replacement Tool

12­892­05

Link

Coolant Management Tool

KL5007NAV

Link

EGR Leak Detection Kit

12­892­02

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.
-If the HT module and mid-plate are "mis-aligned" from the factory, please reference TSI 13-12-18 for resolution.
-The core R&R procedure is NOT 100% effective.There will be instances when the core is caught during removal, stuck during
install, etc, where the half cooler will have to be replaced. For questions or concerns on this, please open a (Big Bore) Tech Services
case file.

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 quickly­­the air pressure in the core passages is still enough to cause bubbles when putting
pressure to the LT.

Figure 1: 2010 MaxxForce 11/13 EGR Cooler Assembly

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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)

*Visual inspection should never be used for diagnosing a bad cooler. The cooler (especially when constantly operated cold--read, moving
the truck around the lot) will cause condensation build­up, and when mixed with soot/exhaust constituents, can be easily confused with
coolant. ALWAYS pressure test the cooler.*

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)

2511089C91

1

For external leaks ONLY, in place of LT Kit

Kit, Low Temp Seal

2512193C91

1

For external leaks between the LT and the plate

Kit, Y­Fitting (Low Temp)

1844447C1

P­80 Assembly Lube

2511097C1

For leaks at LT Y-Fitting (bolt-on ONLY)
1

Case of 6 Pints

NOTE
If the core is damaged during shipping (ie, bent header plate), DO NOT USE it. The packaging is being revised to better withstand the poor shipping handling.
Any stresses on the braze/header will cause an exponential decrease in the core's strength.

'

REPAIR STEPS
REPAIR VIDEO
The entire repair procedure has been put into video and available in the Learning Management System. Go to the
LMS via this link. Then "Course Catalog," "Critical Repair Videos," "HT EGR Cooler Core Replacement Procedure,"
and enroll. After enrolling, go back to "My Current Enrollments" to watch. If you do not see the same link in the course
catalog, do a search (Ctrl "F") and search for "HT EGR Cooler Core Replacement Procedure."

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.

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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

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
open­end wrench.
CAUTION
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. There is a distinct difference between bottoming out on the header plate, and bottoming out in the housing (hard stop). 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).

Notes:
-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.
-NEVER use an impact on the tool. The tool was not designed to handle the stresses because core and/or housing damage will result from the
uncontrolled force. Always use a ratchet.

6.

Unscrew the knobs from the rods.

7.

Remove the cooler core from the housing.

8.

Unscrew the screws from the removal plate/core and discard.

9.

Unscrew the rods to remove the gasket (discard).

Figure 5: HT Diffuser O-Rings
Item 1: HT Housing
Item 2: Manifold (joint) Plate
Item 3: O­Rings

10. Use a pick to remove the four o-rings in the center of the cooler and discard. The o-rings must be replaced every time the core is
replaced. Non-compliance will result in premature failure of the core.

INSTALLATION PROCEDURE:

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Figure 6: HT Diffuser O-Rings
Item 1: HT Housing
Item 2: Manifold (joint) Plate
Item 3: O-Rings

1.

Install the four o-rings from the HT kit (Figure 6, Item 3) and ensure they are seated properly.

NOTE
Make sure there is no debris in the o-ring grooves prior to installing the o-rings (they don't need to be spotless, just no soot chunks that will push the o-ring
out of round). In development, this was the only instance of damaged o-rings (core outlet manifold cut off a section of the o-ring), outside of not actually seating
them.

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Figure 7: Cooler Core Kit O-Rings

CAUTION
There are two o-ring designs and both are the same size with different durometers. Make sure to use only the black o-rings on the HT core and pink o-rings on the
LT core.

2.