From day one, Dura-Lite™ has been committed to solving the Charge Air Cooler durability problems vehicle owner/ operators face. When Dura-Lite™ started on this project, we knew that we had to engineer a Charge Air Cooler that met the required OE engine performance specifications. We also knew we had to produce a Charge Air Cooler which would last - not for months or a couple of years, but for many years! This commitment to Quality and Excellence placed Dura-Lite™ in a unique position. While other Charge Air Cooler manufacturers were attempting to improve upon the typical Charge Air Cooler thermal fatigue failure (OE design), Dura-Lite™ took another approach. 

Dura-Lite™ engineered a Charge Air Cooler incorporating our Patented Silicone Grommet Tube-to-Header Seal System in place of the traditional brazed/ welded tube to header joint. The silicone grommets allow for free thermal expansion while maintaining a leak free seal. This free thermal expansion eliminates the stress and premature failures associated with a restrained brazed/ welded tube to header joint. Strain tests, thermal cycle tests, dynamometer tests, durability tests at elevated temperatures, and field tests were conducted. Dura-Lite™ coolers produced outstanding results and confirmed that our engineers had, indeed, found the solution to eliminating premature Charge Air Cooler failure.