Transmission Oil Cooler

Removal

1. Remove outlet tank from radiator (8005) as outlined in Section 03-03.

2. Remove retaining nuts and washers from transmission oil cooler inlet and outlet connections. Lift transmission oil cooler (7A095) from radiator outlet tank.

3. Remove rubber gaskets from transmission oil cooler inlet and outlet connections if transmission oil cooler is to be reused.

Installation

1. Position transmission oil cooler to radiator outlet tank and insert inlet and outlet connections through holes in outlet tank.

2. Install flat washer and nut on each transmission oil cooler connection to retain transmission oil cooler in radiator outlet tank.

3. Tighten transmission oil cooler retaining nuts to 17-23 Nm (12.5-16.9 lb-ft).

4. Assemble and install radiator as outlined in Section 03-03.

Oil Cooler Steel Lines Using Push Connect Fittings

Removal and Installation

1. If leakage is noted at cooler line fitting on the transmission, remove the cooler line fitting retaining clip. Remove the cooler line using cooler line disconnect tool T86P-77265-AH. Refer to Oil Cooler Line Disconnect Tool Usage.

2. Remove the push-type connector from the radiator and/or transmission case (7005) and discard.

3. Cut off the tube as close as possible to the formed bead using a tube cutter.

4. Slide a 1/4-20 threaded tube nut on the tube.

5. Fabricate a double flare tube end.

6. Install a 1/4x18 straight thread connector into the transmission case , or a 1/4x18 tapered thread connector into radiator , using thread sealer or teflon tape on the male threads of the connector. Tighten to 16-20 Nm (12-15 lb-ft).

7. Install tube nut into connector. Tighten to 16-24 Nm (12-17 lb-ft).

Oil Cooler Line Disconnect Tool Usage for Push Connect Fittings

NOTE: On some applications, it may not be possible to insert the removal tool into the fitting due to vehicle component interference. If this condition exists, the fitting must be removed from the transmission case without disconnecting the oil cooler line. Turning the fitting without removing the oil cooler line may damage the internal O-ring of the fitting causing a leak. If the fitting is removed without disconnecting the oil cooler line first, a replacement angle flared type fitting must be installed. Refer to Oil Cooler Steel Lines Removal and Installation.

For transmission oil cooler line service, cooler line disconnect tool T86P-77265-AH is required. The purpose of the tool is to spread the duck-bill retainer to disengage the tube bead. The following steps are necessary for use of the tool.

To aid in the use of the tool, remove tube retaining clip, and then clean the road dirt from the fitting before inserting the tool into the fitting. Also, it is important to avoid any contamination of the fitting and transmission. Dirt in the fitting could cause an O-ring leak.

1. Slide cooler line disconnect tool T86P-77265-AH over tube.

2. Align opening of tool with one of two tabs on the fitting duck-bill retainer.

3. Firmly insert tool into fitting until it seats against tube bead. (A definite click should be heard).

    CAUTION: Do not attempt to separate cooler line from fitting by prying with another tool. This will break the plastic insert in fitting and bend the cooler lines at junction to fitting.

4. With thumb held against tool, firmly pull back on tube until it disengages from fitting.

   Before assembly of the lines in the fitting, visually inspect the plastic retainer in the fitting for a broken tab. If a tab is broken, the fitting must be replaced. Also visually inspect the oil cooler lines to ensure they are not bent at the junction of the fitting.

   Tube assembly is accomplished by inserting the tube into the fitting until the retainer engages the tube bead. (A definite "click" should be heard). Pull back the tube to ensure full engagement. Install tube retaining clip.