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Discussion Starter #1
Stillen replaced my supercharger a couple weeks ago, because I had gone through 3 intercoolers since August. Each replacement intercooler on the old supercharger only lasted about 1,400 miles. I got about 1,600 out of this one. After an hour of driving the res. level is half empty. Talked with Chuck at Stillen today, and apparently I'm the only one with the problem now. He's going to talk with the GM and get back to me. If any supercharger owners read this, check your intercooler res. level. Is it full? Do your resevoirs stay full, or are you having to add fluid on occasion? This just doesn't make any freakin' sense!!!
 

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chargedTitan said:
Stillen replaced my supercharger a couple weeks ago, because I had gone through 3 intercoolers since August. Each replacement intercooler on the old supercharger only lasted about 1,400 miles. I got about 1,600 out of this one. After an hour of driving the res. level is half empty. Talked with Chuck at Stillen today, and apparently I'm the only one with the problem now. He's going to talk with the GM and get back to me. If any supercharger owners read this, check your intercooler res. level. Is it full? Do your resevoirs stay full, or are you having to add fluid on occasion? This just doesn't make any freakin' sense!!!
Galen had something wrong with his intercooler but I can't remember what.
 

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My resevoir is full. I don't have to add any fluids.
 

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chargedTitan said:
Stillen replaced my supercharger a couple weeks ago, because I had gone through 3 intercoolers since August. Each replacement intercooler on the old supercharger only lasted about 1,400 miles. I got about 1,600 out of this one. After an hour of driving the res. level is half empty. Talked with Chuck at Stillen today, and apparently I'm the only one with the problem now. He's going to talk with the GM and get back to me. If any supercharger owners read this, check your intercooler res. level. Is it full? Do your resevoirs stay full, or are you having to add fluid on occasion? This just doesn't make any freakin' sense!!!
mine is full.
 

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Kronos1965 said:
Galen had something wrong with his intercooler but I can't remember what.
Galen's intercooler was replaced because the manifold was damaged during shipping. To prevent any internal damage to the intercooler from the jarring fall it must have taken we went ahead and sent a new intercooler along with the new manifold.
 

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Discussion Starter #6
Just talked with Chuck at Stillen. Apparently the Titan doesn't like the type of intercooler that currently is being used for one reason or another. They are looking for a new manufacturer to make a bar and plate style intercooler. Chuck says I'll recieve the first one, but it will take 6-8 weeks. In the meantime were going to drain the coolant from the intercooler system and Chuck is overnighting a de-tuned piggyback unit to use in the meantime. Thanks to Chuck for getting back to me promptly with what I am hoping, and my mechanic for that matter, is the final resolution to this problem.:)
 

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so is the black RTV sealant breaking down? Is it the cooler/mani bolts not holding torque right? Or is it the actual fins that are cracking in the mini radiator?
 

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Discussion Starter #8
RB's Titan said:
so is the black RTV sealant breaking down? Is it the cooler/mani bolts not holding torque right? Or is it the actual fins that are cracking in the mini radiator?
The actual fins appear to be cracking. Each one was sent back to Stillen and all I hear back from them is "yeah, it's leaking", not really any explanation on why. My mechanic has pressure tested each one and has found coolant coming from the fins but also where the fins are welded to the end cans.
 

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Thanks...Oh I see...wonder if they will try to provide larger transfer of cooling space with the new cooler.

I've oftened wondered what a dry ice and alchy solution would do to that inner cooler and how much perfromance would be gained. I bet someone could machine adapter plate with a larger cooling surface.
 

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Discussion Starter #10
I've been searching online to try and figure out the differrence between the tube and fin style intercooler currently being used and the bar and plate style they will be switching to. From what I can see it does look like it would be much more efficient at doing its job. I just want one that doesn't dump coolant into my motor!
 

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chargedTitan said:
I've been searching online to try and figure out the differrence between the tube and fin style intercooler currently being used and the bar and plate style they will be switching to. From what I can see it does look like it would be much more efficient at doing its job. I just want one that doesn't dump coolant into my motor!

I'd forget getting the stillen intercooler, go with a GOOD aftermarket AMS intercooler they are well known in the racing market only problem is they are about 600.00 to 1,000 see if you can get stillen to pay for it for ur troubles..
 

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Discussion Starter #12 (Edited)
Toomnymods said:
I'd forget getting the stillen intercooler, go with a GOOD aftermarket AMS intercooler they are well known in the racing market only problem is they are about 600.00 to 1,000 see if you can get stillen to pay for it for ur troubles..
Stillen doesn't actually make their intercoolers. They have been through 2 different manufactures and I've burned through intercoolers from both. I believe the last three were AMS. I just put a call into Chuck and I'll find out for sure and let you know.
I was wrong, I just heard from Chuck. Their most recent manufacturer was CFS.
 

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Have you checked the water pump? I don't think the pump will be that high enough of pressure to break the seal in the intercooler but you have to wonder after 3 intercoolers?
 

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Discussion Starter #14
purplegodzilla said:
Have you checked the water pump? I don't think the pump will be that high enough of pressure to break the seal in the intercooler but you have to wonder after 3 intercoolers?
Actually, it's 4 intercoolers now. Yeah the water pump for the intercooler res. has been replaced 2 times. The system only runs on 1-2 psi. My mechanic pressure tested, not the last intercooler because it came pre-assembled with whole blower assembley , but the intercooler before that to 40 psi., and it still failed after about 1,500 miles. Yes, it does make me wonder? It keeps me up at night wondering.
 

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Discussion Starter #16
Cutler said:
Have you considered looking at Bell Intercoolers?
Yes. I talked with Gerhard 2 weeks ago. He said it would take about 2 weeks to make me an intercooler once they recieved the old one. 2 weeks sounds alot better than 6-8 weeks through a company that Stillen hasn't even decided on yet. I'd rather not have to pay any more money out of my pocket if Stillen is willing to fix it. Maybe I need to get Chuck at Stillen to talk with the guys at Bell.
 

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Tube and fin intercoolers are pretty much the standard intercooler for all forced induction kits in the industry. We have been using them since early 2003 when we came out with the first 350Z supercharger with no problem. Recently we had a couple of Titans specifically that experienced some leaking issues. In an effort to eliminate this problem we have decided to offer a bar and plate intercooler for the Titan Super Charger. Bar and plate heat exchangers by nature are much stronger and therefore almost impervious to leaks and cracks. They aren’t quite as efficient at cooling but the added strength/reliability is worth the trade-off in our mind for a super charger owner that will really “use” their blower.

This isn’t something that current owners need worry about as it seems to be a problem that only occurs on certain vehicles with certain kits. There really does not seem to be any commonality involved. We will offer the bar and plate as an upgradeable kit but it will not be a warranty item unless you experience a failure.
 

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Discussion Starter #18
Tube and fin intercoolers are pretty much the standard intercooler for all forced induction kits in the industry. We have been using them since early 2003 when we came out with the first 350Z supercharger with no problem. Recently we had a couple of Titans specifically that experienced some leaking issues. In an effort to eliminate this problem we have decided to offer a bar and plate intercooler for the Titan Super Charger. Bar and plate heat exchangers by nature are much stronger and therefore almost impervious to leaks and cracks. They aren’t quite as efficient at cooling but the added strength/reliability is worth the trade-off in our mind for a super charger owner that will really “use” their blower.

This isn’t something that current owners need worry about as it seems to be a problem that only occurs on certain vehicles with certain kits. There really does not seem to be any commonality involved. We will offer the bar and plate as an upgradeable kit but it will not be a warranty item unless you experience a failure.
I don't mean to start an issue here, or argument for that matter, so please correct me if I'm wrong. But it seems that you may be insinuating that I "really use my blower". My truck has 19,000 miles on it and I have 16,000 on the supercharger. The s/c was installed last December and I had no problems with it until August, when I started getting engine misfire codes. Since then I've been through 4 intercoolers from 2 different manufacturers. The last three I only got about 1,500 miles out of each, and the most recent was on an entirely new blower assembley. I don't race my truck. The only time I really "use" the S/C is when I want to pass a car going 45 in a 55 zone. And yeah , it's fun to see their faces when a fully loaded crew cab with mud terrains gets up and goes, and passes them like they were standing still. Obviously, other things can cause your intercooler res. level to drop. But, if you are having to fill it every other day, with no signs of leaks , and throwing multiple cylinder misfire codes than yeah, I would worry.
 

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You might have taken my post as being argumentative. I apologize for that, it was not meant to be at all.

We encourage people to use their superchargers as they were designed. Stand on it and have some fun.

I spent a lot of time in the desert and offroading around very rough terrain at high speed and in the boost with my truck and never had a single intercooler failure.

I am not trying to say that the intercooler failing is a result of your driving habits at all.

There is a running joke around Stillen that if I can't break it then no one can. And I never broke the intercooler so we know that it's not your fault, it's just an anomoly.

Just like the supercharger waiver and our instructions state. Part of owning a high performance part like a supercharger is keeping an eye on your coolant levels and routine maintenance. So I definitely encourage all supercharger owners to keep an eye out and regularly inspect your vehicles. That really goes for all owners of modified vehicles.
 

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Discussion Starter #20
Kyle -
I know things are often misunderstood in these posts. Without the tone of someones voice its difficult to tell sometimes what exactly is being said. Thanks for the clarification.
Bob
 
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