Gen.2 tranny cooler install help

[SHOZ123]

I did not remove mine to install the cooler.

 

[SHOZ123]

What I did was drill and tap two 1/4 x 20 holes to hold the cooler. Be forewarned this is a super alloy steel. Very thin but unbelievably hard. You need to start with a very small bit and one bit size at a time increase the hole to the diameter that you want.

 

[DavidT]

yes... I found that out when I mounted my foglights

 

[DavidT]

btw, how hard is it to remove the factory steel lines?
Also, is "2-wire hydraulic hose" what I want to connect the 2 coolers with?

 

[NebraskaSHO]

You need a metric line wrench. They are easy, whats not easy is getting the battery tray out of the way.

Total PITA

Before:


After:

 

[SHOZ123]

You don't need hydraulic hose. Plain tranny cooler line will work. This is a low pressure loop.

 

[DavidT]

I thought you mentioned that an 18" hydraulic hose was needed for the 180 degree bend.
Also, will I lose lots of tranny fluid when I remove the steel lines?

 

[SHOZ123]

I used steel reinforced hydraulic hose so it would not collapse/kink due to the sharp bend. You could use a 180 degree copper or steel line too. Or a lot of regular hose looped so it does not restrict.

 

[NebraskaSHO]

Or a lot of regular hose looped so it does not restrict.

Yep, that's what I did.

Paul, what was the size of those barbs again? M __ x __

 

[SHOZ123]

mNPT 1/4" x 3/8" barbs. I noticed today the OEM tube AUX cooler is smaller than the 3/8" opening like the Gen 2 cooler. Do what you want with that.

 

[DavidT]

will tranny fluid leak out of the tranny when I remove the steel lines?

 

[SHOZ123]

A small amount.

 

[SHOZ123]

I just put new hoses on my car. I used the smaller 11/32" hose (which is OEM size) that I got from BulkParts. This was a bit difficult to get on the 3/8" barbs and 3/8" GEN 2 cooler. With a bit of **** on the hose it will go on though. And lay the hose out in the sun to heat it up helped too.

I also added a inline Magnafine filter. This was put on the inside coming from the upper port on the tranny. This makes for a good place to flush the tranny at.

 

[DavidT]

ok... last question. I promise. well, maybe...
I just want to know exactly what to expect when I begin.
Will I need to remove the front bumper to replace the factory steel lines/ and bypassing the radiator?

 

[NebraskaSHO]

Not the front "bumper" but the cover yes.

Disconnect battery
Remove battery tray
Clean off area around hoses with engine cleaner or compressed air
Remove front bumper cover
Loosen factory hoses
Remove factory hard lines from transmission
Drill holes into bumper for cooler
Install new cooler
Install new barbs into tranny
Install new hoses, tranny to factory cooler, then to aux cooler, aux cooler to tranny
Add fluid
Reinstall battery tray
Reinstall battery
Reinstall bumper cover
Test drive, fill accordingly

 

[SHOZ123]

I just removed the lower splash panel when I originally put mine in.

 

[Flyguyeddy]

when they say that the battery tray is a PITA they are NOT lying!

i did this mod today, and that was one of the worst parts. and there were a few nasty ones as well. removing the stock lines isnt fun. i left the fittings in the radiator, cause when i tried to take them out the radiator started leaking. is that bad?

anyway, the transmission is now cooled by the Gen2 cooler and that aux tube thingy. say goodbye to the radiator cooler.

i WAS going to remove the bumper and take it to work to drill it, but apparently ford thought it would be a great idea to weld it onto the frame as well. thanks fud!

 

[SHOZ123]

Actually the bumper cover is a cinch to remove. Takes maybe 5 minutes.

Just don't forget the one stud on each fender under the inner fender liner.

You should tighten the radiator fittings back up but be careful to not over tighten. If they are no longer leaking it's no problem.

 

[NebraskaSHO]

He meant the actual bumper, not the cover.

It will puke some fluid out when you remove the hard lines, because there is fluid in the lines.

 

[SHOZ123]

One thing I did when I installed my stuff was to open the front up a bit under the bumper cover. The fiberglass part was easily cut out.

I also see on the Gen 4s they come from the factory something like this.