Charge Air Cooler for International 8600 9100 9200 9400 9900 (2007-2009)

Heavy-Duty Aluminum Replacement Charge Air Cooler for 2007-2009 International 8600, 9100, 9200, 9400, 9900 (Navistar 9000i / TranStar Platform)

What it Does: The Charge Air Cooler replaces degraded factory heat exchangers on 2007-2009 International 8600, 9100, 9200, 9400, and 9900 trucks to lower compressed turbo intake temperatures, restore boost pressure, and reduce exhaust gas temperatures (EGT).

The Stock International 8600, 9100, 9200, 9400, 9900 Core Degradation and Joint Fatigue

Factory charge air coolers operating in heavy-duty Class 8 service face continuous thermal expansion cycles and intense road vibration. Over time, the stock tube-to-header joints develop micro-fractures, while internal passages can accumulate soot or road-debris impact damage. A leaking charge air cooler drops manifold boost pressure, causing excessive exhaust gas temperatures (EGT), unburnt fuel resulting in heavy black smoke, increased DPF regeneration frequency, and measurable fuel efficiency loss under heavy load.

The Engineering Solution

Manufactured with high-tensile, brazed all-aluminum construction, this direct-fit charge air cooler restores factory thermal transfer efficiency and intake airflow integrity. Featuring a 39-3/4 inch by 11-5/8 inch core with a 4-inch core depth, the internal extruded tubes withstand elevated boost pressures without seam deformation. Robust 4-inch cast-style aluminum inlet and outlet necks ensure maximum charge airflow and precise alignment with OEM charge boots, matching factory positions without piping modifications. Designed to replace failing units cross-referenced to OEM 2591600C91 and 2608783C91, this unit maintains intake density to optimize combustion efficiency under heavy hauling demands.

What's Included

• 1 Heavy-Duty Aluminum Charge Air Cooler

Technical Specifications

Compatibility

• 2007-2009 International 8600 TranStar
• 2007-2009 International 9100i
• 2007-2009 International 9200i
• 2007-2009 International 9400i
• 2007-2009 International 9900i Eagle
• 2009 International 5500i (with matching OE part number)
• 2009 International 5600i (with matching OE part number)
• 2009 International 5900i (with matching OE part number)

Frequently Asked Questions & Fitment Warnings

Does this fit the Navistar 9000i / TranStar Platform 8600, 9100, 9200, 9400, 9900?

Yes, this is a direct fit for the 2007-2009 International 8600, 9100, 9200, 9400, and 9900 equipped with compatible Cummins ISX, Cat C13/C15, or MaxxForce powerplants; however, it fits only trucks matching the listed OE part numbers, and will not fit vehicles using alternative core dimensions or offset hose configurations.

Should the charge air boots and piping be pressure tested during installation?

Yes, technicians must inspect charge air silicone boots, clean interconnecting piping, torque heavy-duty constant-tension T-bolt clamps, and conduct a full pneumatic pressure decay test before returning the truck to service.

The International Hauling Standard

Engineered to handle severe fleet duty cycles and maximum GCWR cross-country transport, this commercial-grade charge air cooler ensures steady thermal control under prolonged grades and heavy freight demands.