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LX and LXI (Unique Issues) If you have a unique issue with your LX or LXI model coach and it can't be answered in one of the other forums here, then this is where you can list it, WITH THE EXCEPTION OF THOSE ISSUES INVOLVED WITH ANY LAWSUIT.....list your LX and LXI Parts here too.

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  #1  
Old 09-23-2018
alustiza alustiza is offline
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Join Date: Jan 2010
Location: Ouray
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Default Radiator & Charge Air Cooler Replacement

So I took the LXI in to have a leak fixed from the radiator fill tank to the engine about three months ago, and the mechanic replaced the silicon hoses dealing with that area but I asked him if he would check out the rest of the coach and the only problem he could see coming was when he looked at the main radiator for the Detroit, he noticed some color issues with the radiator fins in the lower part of the radiator. He is a heavy truck person, so he knows how to spot this. He indicated at the time, that he didn't know exactly how long it would be until a leak occurred, but that it would eventually happen, so I set up an appointment to have the radiator replaced, which was for this month, being September. The new radiator had to be built, so he removed the radiator, which was a total *****, and he sent it in to the radiator shop in Grand Junction Colorado to be used as a pattern for the new radiator. At the time of the removal one of the mechanic's helpers was supposed to check the Turbo Charger Air Cooler for leaks, but the individual got sick, so he forgot. When the radiator got back, the mechanic went to check the Turbo Charger Air Cooler for leaks and sure enough it had a big one. He felt bad, as it meant that the coach is still in the shop waiting on a new cooler to be built, about 10 days.

The point of this post is after 20 years, most of the radiators in the LXI's are probably reaching their life span. If you decide to have the radiator replaced, have the Charge Air Cooler checked for leaks, as they could both be built at the same time, avoiding the huge delay. The cost for just the manufacture of the radiator is about $3200 and the cost for the charge air cooler is about $2100, not counting removal and installation. At this point in time, a bunch of the hydraulic hoses are also being replaced, as they are hard.
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1999 LXI 43 Body #F123322
Ouray Colorado

Last edited by alustiza; 09-23-2018 at 04:39 PM. Reason: Spelling
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  #2  
Old 09-23-2018
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Randy Dupree Randy Dupree is online now
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This job is in my plan for this winter,my fan motor is weeping,so out comes the rad and the cac,all new hoses and a new fan motor while i'm in there.


Last year we did this job on a 97wb,and we forgot to check the CAC,and it also had a huge leak,so we waiting another week to finish that job.
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2000 LXI 43
Bainbridge,Ga.
Archer Fl.
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  #3  
Old 11-08-2018
crewsro crewsro is offline
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Dan,
I aplogize for being really busy with life. Haven't kept up with all the WOG posts.

I also discovered leaks in both the main raidator and CAC radiators a little over a year ago, and had to have them removed and repaired. Fortunately, the shop manager concurred with the radiator shop I found here in the LA area. They are masters at their trade. They had to send away ( somewhere in the south ) for the CAC aluminum core, then welded the caps to it in-house. They also rebuilt the radiator completely in-house. Luckily, all this remove and replace effort was perfomed in an MCI bus shop close to me. They simply raised the coach off the floor using 6 mobile electric lifts under each tire set. These lifts work in unison and raised the coach allowing easy radiator pack extraction and replacement.

The issue I wish to share is.... the original radiator shop that manufactured our radiators is somehwere in the northwest ( I found and did talk to the owner ), but their radiators have to be manufactured from scratch. That process was long and their cost was about $5000 each. The radiator shop here in Santa Fe Springs ( a neighboring city in the LA Valley ) told me they could make any truck and bus radiator, with all flanges, within a couple weeks time at about 3/4 the cost. I imagine there should be similar experienced radiator shops elsewhere in in the country where there is a lot of truck and bus repair business.
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2000 W.L. 43LXi Millenium
Long Beach, CA

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Old 11-08-2018
Clembo Clembo is online now
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I talked Diana at Dura-lite into selling me a CAC direct. It was a hair over 3 grand delivered to my house. It's a piece of art. The silicone grommet system they use is very cool. It has a 7 yr - 1,000,000 warranty also. Can't beat that.
Dan
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Dan & Diane Clements
2000 LXi 43 2S "Millennium Edition"
1996 WB-42
2006 Trailblazer LT 4wd
Bartow, Fl
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Old 11-08-2018
crewsro crewsro is offline
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Clem,

That’s a great price. I’m so glad this has worked out for you.
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  #6  
Old 12-04-2018
GregOC GregOC is offline
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I was able to pull the radiator out of my lxi by

  • Remove the rear bumper
  • cut the cross member 45deg 1.5x1.5 tube that only serves to hold the gate catch
  • sawzall the upper all threads that hold the rad
  • saw or cut all the old tired rubber flashing
  • keep track of cut bolts and positions
  • build a raceway for the rad to slide out the back with 2 of 2"x3/8flat stock x 6 foot long
  • roll the rad out the back on 3/4 inch x 12 inch round stock.
  • rebuilt the rad and cleaned the cooler in Riverside CA by Stewards radiator. think it was around $3000?.
  • match and measure the two cut upper brackets to make refit easy
  • removal -3 hours, ;clean condition repaint -8 hours, ;reinstall -5 hours one man job (two men would be another 16 hours, twice the diet pepsi)
  • placed luan plywood on sides of cooler and rad while working in and out
  • mark the metal tubes with orientation/ rotation prior to cutting old boots.
On reinstall

  • welded tabs to the gate latch I cut off and reinstalled. I pre mesured a triangle distance thinking that cross pipe was structural however it is just a thin wall offset for the gate latch, however important to get lined up to meet the lock. was going to weld back but wanted to be kind to the NO
  • new tube boots, new rad resting grommets matched from a freightliner setup.,new bands no springs on bands. boots take the flex.
  • made new flashing with new mudflap material
  • did not reinstall the lower rad flashing pans, no issue no noticable heat, even when idling in traffic for 3 hours which was my concern with air re circulation
  • paint with primer and rattle can all of the bands and bolts once set
next time
  • cut out metal down air tube brackets and replace with low move hanger material. I think the down tube needs a bit of movement but need to maintain close ties with the air cooler inlet. as others have had splits there. I think this happens when the boots get old and lose the necessary movement.
  • cut a notch in the huck bolted radiator support that is in the way of sliding out
  • make a new method to reattach one pita bolt lower radiator. was not able to torque with a gauge, huck brace is in the way
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Romoland, California
a SOB with a LXi
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  #7  
Old 12-04-2018
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Randy Dupree Randy Dupree is online now
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Greg,you took that proceedure right out of my playbook,but i used a forklift fork to slide the rad out onto.
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2000 LXI 43
Bainbridge,Ga.
Archer Fl.
www.buybyebluebird.com

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  #8  
Old 12-04-2018
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Mike Hohnstein Mike Hohnstein is offline
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There's a blast from the past^^
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  #9  
Old 12-04-2018
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Quote:
Originally Posted by Mike Hohnstein View Post
There's a blast from the past^^
True!
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2000 LXI 43
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Archer Fl.
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Old 12-04-2018
GregOC GregOC is offline
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We are up in the foothills of the Sierras today and I could heat a high pitch when we passed rocks reflecting noise. I noticed the sound changed to nothing at low boost. I was think it was turbo bearings but .........4 miles from the resort, Pop went the lower hose to the CAC. I need to reset the down metal tube. never felt it lined up proper and didnt want to cinch the hose band down to hold it. thinking the cac would then fail
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