NHTSA ID Number: 10183839
Manufacturer Communication Number: PA-2015-014
TSB/Document Date: 2020-12-07
Summary
Av-Tekk
model engines.
a typical cooler operating with slightly over 400°F inlet temperature will drop the boosted air’s temperature to just
over 100°F before it enters the engine. this drop of nearly 300°F causes extreme thermal stresses from expansion
and contraction of the entire structure. these stresses along with engine load variances and chassis vibrations cause
frequent fatigue failures, the majority being cracked header plates and air tubes (see image below).
CRACKED HEADER PLATES
AIR TUBE CRACKS
Understanding Your Service Options:
2
“FIX AND GO”
“REPLACE & REWELD”
“Av-Tekk NEW & NEW HD”
Putty type fix at a radiator
repair shop is not durable and
often leads to wasted time and
money. it does not strengthen
weak areas that will eventually
fail when placed back
in service.
Complete replacement of the
center section or “brick” is
good but very expensive and
is subject to the quality of the
replacement brick
av-tekk’s new and new
hD units require no core and
both offer superior quality
and performance. these
completely new replacement
coolers are available in several
high volume applications.
LOW COST/LOW QUALITY
HIGH COST/HIGH QUALITY
LOW COST/HIGH QUALITY
NOT COMMERCIALLY
ACCEPTABLE!
OK SOLUTION!
BEST SOLUTION!
Saving Money with Av-Tekk
the av-tekk brand means av-tekk solutions. our brand has been revolutionizing the charge-air cooler industry
since the very beginning. we have made it our mission to improve the durability and experience of all diesel
charge-air coolers. From the introduction of the only Faa approved rebuild process for charge-air coolers, to
our amazing heavy duty bar and plate designs, av-tekk is constantly working to improve our brand through the
quality of products we provide. even now when the industry is asking more of its diesel charge-air coolers, avtekk’s products stand above the rest.
Typical Tube & Fin
Av-Tekk New HD
Our “Heavy-Duty” bar and plate construction, denoted by “HD” on the part number suffix, is the most
rugged and durable type of construction and is backed by our 5-year/unlimited mileage warranty. the
“hD” coolers are available on most popular applications where experience has shown they are needed.
ALL MAKES CHARG
• Industry’s Best Charge-Air Coolers
• Broadest Service Network
• Nation Leading Warranty
• Priced Right for Highest Value
®
HD
ALL M
av-tekk’s hD design uses a series of heavy
bars and plates to form a stronger cooler and
eliminate the header plate and the fragile
air tubes permitting the manifolds to be welded
directly to the bars in the construction process.
Example of Tube & Fin
construction using a header
plate, typical of most
OEM designs.
Industry studies have shown header plate thermal fatigue
failures and air tube leaks account for the majority of
charge-air cooler failures.
Example of Av-Tekk’s
Heavy Duty Bar & Plate
Construction Design
3
TM
Are you testing coolers
to see if they are
leaking beyond
O.E.M. specifications?
Quick Check Advantages
• No other special tools needed
• Quickest and easiest connections available
• Simulates a constant air load for
accurate diagnostics
• Fits most charge air cooler connection types
• Relief valve and restraints for safety
• Includes compact carrying case
THIS COMPLETE KIT COMES WITH
ALL ADAPTERS AND FITTINGS TO
TEST ALL TRUCK SIZES, PICKUPS
THRU CLASS 8 TRACTORS.
ORDER PART NUMBER A351CAS
For More on Quick Check leak test Kit Go online to: www.av-tekk.com
Av-Tekk’s new Test Kit may be used to test the pressure
drop of most known sizes of charge-air coolers (C AC).
According to most O.E. Manufacturer’s Specifications,
charge-air coolers that show a static pressure drop greater
than 5 PSI in a 15 second test, beginning at 30 PSI, should
be replaced. Av-Tekk’s new CAC Test Kit provides tools for
you to safely determine whether any CAC passes or fails
the manufacturer’s test.
IMPORTANT!
USING HIGH AIR PRESSURES AND LARGE TEST
PLUGS MAY PRODUCE DANGEROUS RESULTS!
Please read the warnings supplied with the test kit before
following these instructions.
The test plugs in this set are heavier duty than most.
Notice that each has a thicker washer to prevent cupping
when you tighten the test plugs in the opening. They also
have 4” long cast handles that permit you to tighten them
more easily.
Inspect the inside of the opening and the test plug rubber,
to make sure both of these surfaces are clean and dry.
Test plugs should be installed flush with the opening and
tightened firmly by hand. Install the Test Plug Clamp,
positioning it over the handle so the notched portion of the
4
clamp engages the outside of the inlet/outlet just behind
the bead. Hand tighten the long wing bolts equally, and
check again to make sure that the notched portion of the
clamp is engaged behind the bead at four points. Hand
tighten the wing bolts until snug or use an open-end
wrench to tighten. Do not over tighten!
If the cooler has been removed from the vehicle, position
it so the open stem is pointing up. Next, connect the brass
tester at the quick disconnect side. This tester is equipped
with a pop-off safety valve that has been preset to 35 lbs
maximum pressure. DO NOT CHANGE THIS SETTING
OR TAMPER WITH THIS DEVICE IN ANY MANNER.
Keep this safety valve clean and dry. Check it occasionally
to make sure that it releases pressure at the 35 lbs setting.
Replacement safety valves and other parts are available if
ever needed.
After checking to make sure everything is properly
secured, introduce air through the air stem using a
common tire chuck. Increase the air pressure to precisely
30 PSI and then measure the pressure drop, if any, for a
period of 15 seconds.
As soon as you have finished testing the charge-air cooler,
return all parts of this set to the plastic case provided, and
close it to keep them clean and dry for their next use.
TM
These complete kits have both
hoses and clamps to replace
ALL hosing from charge-air
cooler inlet and outlet.
Both hoses contained in the
Av-Tekk Hose and Clamp Kits
are hot side compatible.
Now order one part number to get everything you need to
replace ALL hosing for the charge-air cooler.
Av-Tekk Hose & Clamp Kits
Part no.
14000
24045
33375
43500
53875
63000
74500
83037
93040
10250
11334
12278
13358
14318
15316
16278
Inlet size
4”
41⁄2”
33⁄8”
31⁄2”
37⁄8”
3”
41⁄2”
3”
4”
21⁄2”
33⁄4”
27⁄8”
31⁄2”
31⁄8”
311⁄16”
31⁄2”
Outlet size
4”
4”
33⁄8”
31⁄2”
37⁄8”
3”
41⁄2”
33⁄8”
3”
21⁄2”
33⁄4”
27⁄8”
31⁄8”
31⁄8”
311⁄16”
27⁄8”
Av-Tekk Individual Hoses and Clamps
Av-Tekk Hose
Part no.
463-2500-6
463-2875-6
463-3000-6
463-3125-6
463-3375-6
463-3500-6
463-3687-6
463-3750-6
463-3875-6
463-3937-6
463-4000-6
463-4000-8
463-4500-6
463-4500-8
Hose Size
21⁄2” x 6”
27⁄8” x 6”
3” x 6”
31⁄8” x 6”
33⁄8” x 6”
31⁄2” x 6”
311⁄16” x 6”
33⁄4” x 6”
37⁄8” x 6”
315⁄16” x 6”
4” x 6”
4” x 8”
41⁄2” x 6”
41⁄2” x 8”
Av-Tekk Clamp
Part no.
b9226-0256b
b9226-0306b
b9226-0356b
b9226-0406b
b9226-0456b
Clamp Size
21⁄2”
3”
31⁄2”
4”
41⁄2”
to determine corresponding hose and Clamp kit for your cooler, see dimensional drawing section of this catalog.
5
OEM PART NUMBER CROSS REFERENCE
ADVANCE MIXER
OEM Part #......................... Av-Tekk Part #
83441231...........................AM-2A NEW HD
83441411............................AM-2A NEW HD
834411411..........................AM-2A NEW HD
843004123.........................AM-2A NEW HD
843041230.........................AM-2A NEW HD
8430412203.......................AM-2A NEW HD
8430412301.......................AM-2A NEW HD
00D00412301.................... AM-2A NEW HD
35D00412301.....................AM-2A NEW HD
84304123-1........................AM-2A NEW HD
NX4123-1 CAC.................AM-2A NEW HD
BLUE BIRD
OEM Part #......................... Av-Tekk Part #
1030010..............................NV-8A NEW HD
1030020..............................NV-8A NEW HD
1030068.....................................NV-8B NEW
1453232..............................NV-8A NEW HD
123-6645.............................NV-8A NEW HD
271-1453232.......................NV-8A NEW HD
271-1486943.......................NV-8C NEW HD
271-1536499..............................NV-8B NEW
CHEVROLET
/GMC/GENERAL
OEM Part #......................... Av-Tekk Part #
15801...................................... CG-65A NEW
69594..................................NV-8A NEW HD
103188.................................... CG-65A NEW
817120.................................... CG-65A NEW
817120.................................... CG-65A NEW
1030042.................................. CG-65A NEW
1030109.................................. CG-65C NEW
1030184.................................. CG-65C NEW
1030187.................................. CG-65C NEW
1030188.................................. CG-65A NEW
5243119................................... CG-65A NEW
9707160.................................. CG-65A NEW
9707161.................................. CG-65A NEW
15029270................................ CG-65C NEW
15078353................................ CG-65A NEW
15149316................................ CG-65C NEW
15741292................................ CG-65A NEW
15982676................................ CG-65C NEW
52453119................................. CG-65A NEW
91110101................................. CG-65A NEW
97071601................................ CG-65A NEW
105078353.............................. CG-65A NEW
1030042ES.............................. CG-65A NEW
BTC1160................................. CG-65A NEW
DODGE TRUCK
OEM Part #......................... Av-Tekk Part #
222006.................................... DG-70B NEW
817151.................................... DG-70B NEW
1030182.................................. DG-70B NEW
52027562................................ DG-70B NEW
52028724................................ DG-70B NEW
52028724AC........................... DG-70B NEW
83403D.................................... DG-70B NEW
6
FLEXLINER
OEM Part #......................... Av-Tekk Part #
1E4031.......................... FLE-190B NEW HD
FORD/STERLING
OEM Part #......................... Av-Tekk Part #
100327...............................FD-25F NEW HD
160327...............................FD-25F NEW HD
200500.............................. FD-25A NEW HD
200520.............................. FD-25A NEW HD
200521.............................. FD-25A NEW HD
200597.............................. FD-25A NEW HD
202800.............................. FD-25B NEW HD
202820.............................. FD-25B NEW HD
202821.............................. FD-25B NEW HD
326132..................................... FD-25L NEW
1003241.............................FD-25F NEW HD
1003251.............................FD-25F NEW HD
1003254.............................FD-25F NEW HD
1003265.............................FD-25F NEW HD
1003271.............................FD-25F NEW HD
1003273.............................FD-25F NEW HD
1003274.............................FD-25F NEW HD
1003275............................ FD-25A NEW HD
1003281.............................FD-25F NEW HD
1003304............................FD-25G NEW HD
1003306............................FD-25G NEW HD
1003371.............................FD-25F NEW HD
1003372.............................FD-25F NEW HD
1003373.............................FD-25F NEW HD
1030080.............................FD-25F NEW HD
1030097...................................FD-25O NEW
1030098...................................FD-25N NEW
1030100................................... FD-25L NEW
1030104............................FD-25G NEW HD
1030112..............................FD-25F NEW HD
1030113..............................FD-25F NEW HD
1030128...................................FD-25N NEW
1030133.................................FD-25N2 NEW
1030161.................................FD-25N2 NEW
1030226...................................FD-25O NEW
1030227...................................FD-25N NEW
1030245.................................FD-25N2 NEW
1030247...................................FD-25O NEW
1030249.................................FD-25N2 NEW
1040001...................................FD-25O NEW
1040002...................................FD-25N NEW
1040003...................................FD-25N NEW
1040014................................... FD-25L NEW
1040016................................... FD-25L NEW
1040022................................... FD-25L NEW
1040023................................... FD-25L NEW
1040024...................................FD-25N NEW
1040025...................................FD-25N NEW
1040040.................................FD-25N2 NEW
1040050............................FD-25G NEW HD
1040063...................................FD-25N NEW
1040111....................................FD-25N NEW
1040135................................... FD-25L NEW
1040142...................................FD-25N NEW
1040145...................................FD-25O NEW
1050001................................... FD-25L NEW
1050014................................... FD-25L NEW
1050040................................... FD-25L NEW
1050052...................................FD-25N NEW
FORD/STERLING (cont.)
OEM Part #......................... Av-Tekk Part #
1050053...................................FD-25N NEW
1050056...................................FD-25O NEW
1050063................................... FD-25L NEW
1050069...................................FD-25O NEW
28013716.......................... FD-25A NEW HD
85103368.......................... FD-25A NEW HD
85103369...........................FD-25F NEW HD
007905L................................... FD-25L NEW
011288L.............................FD-25F NEW HD
016444L.............................FD-25F NEW HD
0447552L...........................FD-25F NEW HD
047237L...................................FD-25N NEW
1040001M................................FD-25O NEW
1E 3246............................. FD-25A NEW HD
1E 3248............................. FD-25B NEW HD
1E 3396............................. FD-25A NEW HD
1E 3436............................. FD-25A NEW HD
1E 3507............................. FD-25A NEW HD
1E 3526............................. FD-25B NEW HD
1E 3528............................. FD-25B NEW HD
1E 3539............................. FD-25A NEW HD
1E 3708............................. FD-25A NEW HD
1E 3709............................. FD-25A NEW HD
1E 3710............................. FD-25A NEW HD
1E 3712............................. FD-25A NEW HD
1E 3716 ............................ FD-25B NEW HD
1E 3717............................. FD-25B NEW HD
E7HZ6K775D................... FD-25B NEW HD
E8HT14A284AC.............. FD-25A NEW HD
E8HT6K775 ..................... FD-25B NEW HD
E8HT6K775AB................ FD-25A NEW HD
E8HT6K775AG................ FD-25A NEW HD
E8HT6K775ED................. FD-25B NEW HD
E8HZ6K775G .................. FD-25B NEW HD
E8HZ6K775H................... FD-25A NEW HD
E8HZ6K775J.................... FD-25B NEW HD
E9HZ6K775C................... FD-25A NEW HD
E9HZ6K775G................... FD-25A NEW HD
EDE8HT6K775AE........... FD-25A NEW HD
EDE8HT6K775AF........... FD-25A NEW HD
EDE8HT6K775EC........... FD-25B NEW HD
EDE8HT6K775EC........... FD-25B NEW HD
F0HT6K775CA ................ FD-25A NEW HD
F0HT6K775EA................. FD-25B NEW HD
F0HT6K775EB................. FD-25B NEW HD
F0HZ6K775A .................. FD-25A NEW HD
F0HZ6K775AC ............... FD-25A NEW HD
F0HZ6K775D .................. FD-25B NEW HD
F1HZ6K775B................... FD-25A NEW HD
F1HZ6K775D................... FD-25A NEW HD
F1HZ6K775E.................... FD-25A NEW HD
F2HX6K775B................... FD-25A NEW HD
F2HZ6K775B....................FD-25F NEW HD
F3HT8009NA .................. FD-25A NEW HD
F3HZ6K775J ................... FD-25B NEW HD
F4HT8009AAA ................FD-25F NEW HD
F4HT8009AB....................FD-25F NEW HD
F4HT8009AC....................FD-25F NEW HD
F4HT8009AEA .................FD-25F NEW HD
F4HT8009ARA........................ FD-25L NEW
F4HT8009BB.....................FD-25F NEW HD
F4HT8009CB.....................FD-25F NEW HD
F4HT8009CB-039347L.....FD-25F NEW HD
OEM PART NUMBER CROSS REFERENCE
FORD/STERLING (cont.)
FORD/STERLING (cont.)
FREIGHTLINER (cont.)
OEM Part #......................... Av-Tekk Part #
F4HT8009CC ....................FD-25F NEW HD
F4HT8009DD....................FD-25F NEW HD
F4HT8009MB....................FD-25F NEW HD
F4HT8009MC....................FD-25F NEW HD
F4HT8009TB....................FD-25G NEW HD
F4HT8009TD....................FD-25G NEW HD
F4HT8009UD...................FD-25G NEW HD
F4HZ6K775A ...................FD-25F NEW HD
F4HZ6K775B....................FD-25F NEW HD
F4HZ6K775E.....................FD-25F NEW HD
F4HZ6K775F ...................FD-25G NEW HD
F4HZ6K775GA.......................FD-25N NEW
F5HT8009ABA..................FD-25F NEW HD
F5HT8009ADA.................FD-25F NEW HD
F5HT8009AFA..................FD-25F NEW HD
F5HT8009LA ....................FD-25F NEW HD
F5HT8009MA....................FD-25F NEW HD
F5HT8009NA....................FD-25F NEW HD
F5HT8009RA ....................FD-25F NEW HD
F5HT8009UA ...................FD-25F NEW HD
F5HT8009YB...................FD-25G NEW HD
F5HT8009ZB....................FD-25G NEW HD
F6HS8009BA.....................FD-25F NEW HD
F6HS8009BA.....................FD-25F NEW HD
F6HS8009DA....................FD-25G NEW HD
F6HT8009AD.......................... FD-25L NEW
F6HT8009AKD....................... FD-25L NEW
F6HT8009BB.........................FD-25N2 NEW
F6HT8009BD........................FD-25N2 NEW
F6HT8009CB.........................FD-25N2 NEW
F6HT8009DA ..................FD-25G NEW HD
F6HT8009EE...........................FD-25N NEW
F6HT8009HE...........................FD-25O NEW
F6HT8009KE...........................FD-25N NEW
F6HZ6K775A....................FD-25F NEW HD
F6HZ6K775FA......................FD-25N2 NEW
F6HZ6K775GA.......................FD-25N NEW
F6HZ6K775HA.......................FD-25N NEW
F6HZ6K775JA.........................FD-25O NEW
F6HZ80009CB...................FD-25F NEW HD
F7HT80095C...........................FD-25N NEW
F7HT8009ATA......................... FD-25L NEW
F7HT8009BCA........................ FD-25L NEW
F7HT8009EB........................... FD-25L NEW
F7HT8009FB........................... FD-25L NEW
F7HZ9008BNA........................ FD-25L NEW
F86309..................................... FD-25L NEW
F8HS8009AA........................... FD-25L NEW
F8HS8009AB........................... FD-25L NEW
F8HT8009ABA........................FD-25N NEW
F8HT8009ACA........................FD-25N NEW
F8HT8009BA........................... FD-25L NEW
F8HT8009CA........................... FD-25L NEW
F8HT8009EA.........................FD-25N2 NEW
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TSB/Document ID: PA-2015-014
Replacement Service Bulletin Number:
MFR Communication Date: 2015-02-11
MFR Internal Campaign ID/Software Version:
Communication Type: Service Bulletin/Repair Instructions
NHTSA Components: EQUIPMENT
MFR Component System:
MFR Component Subsystem:
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- 【✨Deep Diagnostics for All Vehicle System Modules】Beyond code reading/clearing and ECU information retrieval, our all-in-one data stream feature lets you inspect all current fault codes and their locations across the vehicle’s systems. This vehicle code reader helps you turn off dashboard warning lights and perform a comprehensive self-check of your car at home—no more back-and-forth trips to the repair shop or hefty inspection fees.
- 【✨6 Essential Resets: ABS Bleeding, Oil, EPB, SAS, Throttle, BMS】The BOSSCOMM IF745 obd2 scanner diagnostic tool swiftly purges air from brake lines to restore braking sensitivity, fine-tunes maintenance cycles to eliminate false alerts, resolves parking brake issues with one-click control, recalibrates steering sensors for stability, optimizes engine idling/acceleration for smoother performance, and deeply resets battery systems to extend lifespan and range via precise parameter adjustments.❗NOTE: Does NOT support bidirectional control, coding, or programming.
- 【✨10,000+ Car Models, AutoVIN, 13 Languages】The BOSSCOMM IF745 vehicle scanner diagnostic tool covers 73+ global car brands and offers support in 13 languages, making it perfect for DIYers, auto mechanics, or as a thoughtful gift. With a single-click AutoVIN feature, it instantly retrieves vehicle serial numbers, streamlining diagnostics for users globally. This adaptable tool balances user-friendliness with precision, catering to both personal and professional requirements.✅Unsure about compatibility? Compatibility will vary on vehicles' model and year, pls reach us via 📧 [email protected] 📧 before purchase.
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