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2009 Prostar Coolant Leak Mystery Please Help

Discussion in 'Trucks [ Eighteen Wheelers ]' started by 68Goat, Oct 4, 2013.

Page 1 of 3
  1. Oct 4, 2013 #1
    68Goat

    68Goat Light Load Member

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    Jan 4, 2013
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    Ok, I have a 2009 Prostar. Lately we have been losing coolant in the truck. About a gallon every three days.
    Friday of last week, my regular shop completed a full pressure test on the coolant system. The only thing they were able to find was some slight condensation at the exhaust doser valve. We replaced the valve (expensive part) and it doesn't seem to have worked. There aren't any abvious leaks what so ever. It seems to be happening on the road. Any ideas out there? This truck has been problematic to say the least for us...Any help would be appreciated.
    Thanks
     
    68Goat, Oct 4, 2013
    68Goat, Oct 4, 2013
    #1
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  3. Oct 4, 2013 #2
    Grey Dodge

    Grey Dodge Light Load Member

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    May 16, 2012
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    If it's an ISX Cummins I'd check the EGR cooler! Mine had 6+ gallons of coolant in it.
     
    Grey Dodge, Oct 4, 2013
    Grey Dodge, Oct 4, 2013
    #2
    flood, Loose Leaf and 68Goat Thank this.
  4. Oct 4, 2013 #3
    68Goat

    68Goat Light Load Member

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    Crap, yes I forgot to list that it is an ISX. Where is the EGR cooler located? Is it in line with the coolant system? How could it hold that much coolant? Forgive me, I'm more familiar with N14's and 60 series Detroits.
     
    68Goat, Oct 4, 2013
    68Goat, Oct 4, 2013
    #3
  5. Oct 4, 2013 #4
    deming807

    deming807 Medium Load Member

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    Jul 31, 2013
    Summit IL
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    If you made full pressure test correctly and it passed it, thats not EGR. See leakage on pump, bottom hose to radiator, heaters.
     
    deming807, Oct 4, 2013
    deming807, Oct 4, 2013
    #4
    68Goat Thanks this.
  7. Oct 4, 2013 #5
    Heavyd

    Heavyd Road Train Member

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    Pull the air to air hose off on the intake side of the engine and look down the pipe where the EGR mixing pipe is bolted to the intake pipe. If it is wet with lots of black sludge, your cooler is leaking. Some coolers will only leak once they are hot with the engine, so they may pass a pressure test when warm or cold.
     
    Heavyd, Oct 4, 2013
    Heavyd, Oct 4, 2013
    #5
    truckmechanic and 68Goat Thank this.
  8. Oct 4, 2013 #6
    JPenn

    JPenn Road Train Member

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    EGR cooler is leaking when hot. Replace it now before it causes more problems. I've seen trucks eating upwards of a gallon a day with no perceptible leaks, and that's been the diagnosis every time (with an ISX).
     
    JPenn, Oct 4, 2013
    JPenn, Oct 4, 2013
    #6
    flood, truckmechanic and 68Goat Thank this.
  9. Oct 4, 2013 #7
    o/otony

    o/otony Light Load Member

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    Dec 25, 2012
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    bostech egr coolers,
     
    o/otony, Oct 4, 2013
    o/otony, Oct 4, 2013
    #7
    68Goat and truckmechanic Thank this.
  10. Oct 5, 2013 #8
    68Goat

    68Goat Light Load Member

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    OK, we're gonna get into it tomorrow. Thanks for all the posts.
     
    68Goat, Oct 5, 2013
    68Goat, Oct 5, 2013
    #8
  11. Oct 5, 2013 #9
    68Goat

    68Goat Light Load Member

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    We did replace lower radiator hose earlier this year but that leak was obvious.
     
    68Goat, Oct 5, 2013
    68Goat, Oct 5, 2013
    #9
  12. Oct 5, 2013 #10
    truckmechanic

    truckmechanic Medium Load Member

    534
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    Jan 14, 2012
    Hi Desert Ca
    0
    Be prepared it's an expensive fix and will not be your last if it has failed they need to replace the boost sensor Cvc filter check and clean the erg valve and dpf/doc if this is a isx15 easy way to tell if you might have a failed erg cooler is by the weep hole in the erg valve 90% or the time when you lose a cooler you will have a black soot trail leaking out also tale tale sign on an isx12
     
    truckmechanic, Oct 5, 2013
    truckmechanic, Oct 5, 2013
    #10
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