Oil Cooler and Draincock

Copper/Brass Radiator

Soldered-Type

Replacement of the soldered-type automatic transmission oil cooler or radiator draincock in the radiator lower or side tank, as given below, is usually performed by radiator specialty shops on a sublet basis. However, the operation can be performed in a dealer service department, providing proper equipment is available.

 CAUTION: Only manufactured gas or natural gas torches should be used to perform radiator service. Do not use acetylene.

 CAUTION: No attempt should be made to service a fractured radiator tank. Should a fractured tank be encountered, it must be replaced. Tank repairs usually result in repeat failures, due to the flexing of the tank caused by pressure increase and decrease.

Removal

1. Drain the cooling system.

2. Remove the radiator from vehicle as outlined.

    CAUTION: During the disassembly and assembly solder operation of radiator components, avoid excess heat concentration which could result in burning through the radiator sheet metal or loosening an adjoining soldered area.

3. Thoroughly clean the radiator assembly internally and externally by submerging it in a tank filled with a caustic solution. Then, using clean water, flush until the caustic solution is removed from all internal and external surfaces.

4. Remove the radiator tank containing the damaged or leaking oil cooler. (Tank removal is not necessary for service of draincock).

5. Melt the puddled solder from the oil cooler inlet and outlet fittings. Remove the retaining rings from the fittings in the oil cooler.

6. Remove the oil cooler or draincock.

7. Clean the soldered surface areas and inspect and tin as necessary to ensure proper solder bonding.

Installation

1. Draincock: Position the replacement draincock or draincock boss in the tank opening and solder using the procedures for oil cooler.

   NOTE: If one-piece draincock is not available, a threaded boss (-8120-) and draincock (-8115-) must be used. Solder the boss into the tank following the procedure for one-piece draincocks, then wrap the draincock threads with sealer tape and install the draincock in the boss. Tighten the draincock to 16-20 Nm (12-14 lb-ft).

   Oil Cooler: Install the replacement oil cooler assembly into the tank openings and secure cooler with new retaining rings. For threaded design, tighten retainer to 2-6 Nm (18-53 lb-in). For bead design, push ring past fitting bead. Retaining ring tangs should point away from tank.

2. Puddle-solder the oil cooler fittings completely to the tank.

3. Seat the tank assembly in the header well and solder securely, completely filling the well. Use 40-60 solder with either zinc chloride 30 (BAUME) or 5-B NALCO flux.

4. Flush off all excess acid, internally and externally.

5. Pressure test the radiator assembly to 132-144 kPa (19-21 psi) for leaks.

6. Paint as required.

7. Install the radiator and fan shroud in the vehicle. Install the connectors in the oil cooler inlet and outlet fittings and connect the transmission oil cooler lines. Tighten fittings to 16-23 Nm (12-16 lb-ft).

8. Connect the hoses to the radiator inlet and outlet connectors.

9. Flush the cooling system and refill with the recommended mixture of all-season coolant as outlined in Adjustments.