Charge Air Cooler for International 9400 (1997-2006)

Heavy-Duty Cross-Flow Replacement Charge Air Cooler for 1997-2006 International 9400 (9000 Series SBA)

What it Does: The Charge Air Cooler cools compressed turbocharger air on the 1997-2006 International 9400 to lower intake manifold temperatures, eliminate boost leaks, and recover lost engine power.

The Stock International 9400 Intercooler Core Breakdown

Line-haul duty cycles subject the factory heat exchanger to severe thermal expansion and continuous high-boost cyclic loads. Over time, the original core develops tube-to-manifold micro-cracks, brazed seam separation, and internal fin corrosion. This causes significant pressure drops and intake air leaks, resulting in elevated pyrometer exhaust gas temperatures (EGTs), low manifold boost, excessive black smoke under load, and severe fuel mileage degradation on the 9000 Series SBA chassis.

The Engineering Solution

Engineered as a direct OEM-dimensional drop-in, this aluminum cross-flow charge air cooler restores factory intake density and manifold pressure. High-strength aluminum construction and reinforced header plates withstand continuous 30+ PSI heavy-haul boost pressures without core ballooning or fatigue. Optimized interior micro-extruded tubes and external fin density maximize heat rejection while minimizing static pressure drop, direct-matching OEM factory inlet and outlet positions for part numbers 1E3594, 1698844C91, and 2502984C1.

What's Included

• 1 Charge Air Cooler

Technical Specifications

Compatibility

• 1997-2006 International 9400 and 9400i
• 1994-1999 International 8200
• 1998-2003 International 9100
• 1997-2003 International 9200
• 1999-2007 International 9900

Frequently Asked Questions & Fitment Warnings

Does this fit the 9000 Series SBA 9400?

Yes, this is a direct fit for the 1997-2006 International 9400 equipped with the Cummins ISX / Cat C15 engine platform. Fits only trucks matching the specific OE part numbers and dimensions listed above; verify existing core measurements prior to ordering.

What service steps must be completed during installation?

Decontaminate charge air pipes, install fresh silicone boots with high-torque spring clamps, and complete a pneumatic pressure decay test prior to operation.

The International Severe-Duty Standard

Heavy-haul transport requires sustained heat dissipation and robust mechanical integrity to ensure maximum pulling torque across mountain grades without thermal derate or boost failure.