Charge Air Cooler for International ProStar (2008-2009)

Heavy-Duty Aluminum Charge Air Cooler for 2008-2009 International ProStar (Navistar ProStar)

What it Does: The Charge Air Cooler cools compressed turbocharger discharge air on 2008-2009 International ProStar trucks to restore intake air density, lower exhaust gas temperatures, and prevent boost pressure loss.

The Stock International ProStar Intercooler Fatigue and Leakage

Factory charge air coolers operating on heavy-haul commercial platforms undergo intense thermal cycling and high manifold gauge pressure. Over time, constant cyclic heat loads and road chassis vibration cause micro-cracking at the tube-to-header plate joints and core-to-tank seams. A leaking or internally fouled cooler compromises the entire induction cycle, causing severe boost pressure drops, elevated exhaust gas temperatures (EGTs), excessive soot generation (black smoke), and unburned fuel waste across severe duty cycles.

The Engineering Solution

Built with an all-aluminum bar-and-plate/tube-and-fin core structure, this replacement intercooler delivers optimal heat dissipation and withstands severe sustained boost pressures without splitting. Sized precisely to factory dimensions—featuring a 39-3/4 inch core height, 11-5/8 inch core width, and a robust 4-inch core thickness—it drops directly into the OEM front frame mounting points. With standard 4-inch inlet and outlet connections positioned identically to original factory routing, it restores turbocharger compressor efficiency, stabilizes air-fuel ratios, and eliminates thermal derating under maximum torque demands.

What's Included

• 1 Charge Air Cooler

Technical Specifications

Compatibility

• 2008-2009 International ProStar
• 2009 International 5500i (with matching OE numbers)
• 2009 International 5600i (with matching OE numbers)
• 2009 International 5900i (with matching OE numbers)

Frequently Asked Questions & Fitment Warnings

Does this fit the Navistar ProStar?

Yes, this is a direct fit for the 2008-2009 International ProStar equipped with the MaxxForce 13 or Cummins ISX platform, provided the original cooler matches one of the specified cross-reference part numbers. It fits only trucks configured with matching OE part numbers listed above.

Should the induction system be pressure tested during installation?

Always inspect and clean silicone boots, replace worn T-bolt clamps, and perform a full pneumatic leakdown test on the charge air tract prior to returning the vehicle to highway service.

The International Hauling Caliber

Engineered for high-mileage freight transport, severe grade climbs, and prolonged GCWR conditions, this cooler ensures unyielding thermal recovery and boost retention under the most punishing heavy-duty hauling environments.