Aftercooler corrosion on 5.9 qsb

[worldcatlemon]

How much corrosion/pitting on the sealing surface between the core and the housing is ok to just grease up and reassemble?

And would it be beneficial to have the surface machined smooth then reassemble?

Thanks

Topic

[Fireisland1]

Assemble as per SBM and pressure test. You may not have any issue

[worldcatlemon]

I will have to take some pics of the o-ring surface tonight. I can feel an indentation on part of the surface where the o-ring sits.

[Rob Schepis]

Any good pics of what you are seeing there?

I just reread my prior post —- To be 100% thorough I should also add that the third sealing surface is the bevel on the underside of the end caps but all that those usually require are a good cleaning.

[worldcatlemon]

Roger that. The face of mine has a groove and looks like it had a slight leak due to the green stain on the cap. So would it be prudent to have it machined smooth ?

[Rob Schepis]

The only “sealing surface” is where the o-ring rides on the housing machined flat end face and on the core end ring outer diameter.

[worldcatlemon]

The o-ring surface has a groove worn into the face but I am more concerned about the 1″ sealing surface where the outer core flange seals to the aftercooler housing.

[Rob Schepis]

Are you looking at the housing inner area or the flats (faces) where the o-rings ride. Unless it’s more than what the pictures are portraying, the faces look good to me. A little block sanding and wp grease is all.

[worldcatlemon]

Aftercooler corrosion is noticeable to the touch.

I thought about lightly sanding, degreasing and spraying an epoxy filler primer to fill the pits then spray “metal black” to seal it up or an epoxy sealer.

What are your thoughts?

The engines only have 260 hours

[Tony Athens]

Post good pictures showing all–No other way to get an answer..

Tony

[Author]

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