From Day One, Dura-Lite™ has been committed to solving the charge air cooler durability problems truck owner/operators face. When Dura-Lite™ started on this project, we knew that we had to engineer a charge air cooler that met required OEM engine performance specifications. We also knew we had to produce a charge air cooler which would last – not for months or a couple of years, but for many years! This commitment to Quality and Excellence placed Dura-Lite™ in a unique position. While other aftermarket charge air cooler manufacturers were attempting to improve upon the OEMs’ designs, Dura-Lite™ took another approach.

We engineered a charge air cooler incorporating a silicon grommet that created our Patented Seal System at the tube to header joint in place of the traditional brazed/welded tube to header joint. The silicon grommets, in effect, allow for free thermal expansion while maintaining a leak free seal. This free thermal expansion eliminates the stress and premature failures associated with a restrained brazed/welded tube to header joint. Strain tests, thermal cycle tests, dynamometer tests, durability tests at elevated temperatures and field tests were conducted. Dura-Lite™ coolers produced outstanding results and convinced our engineers that we had, indeed, found the solution to eliminating premature charge air cooler failure.