Help! Trans cooler line replacement - Diesel Forum

Jon Pletcher · 10-09-2008, 08:03 AM

All stock 02, bought 2 months ago. Corroded trans pressure line that comes out of the radiator beside the coolant hose and runs back to the front of the tranny. Got the new one, disconnected the fittings on the old one and can't seem to jiggle it forward or back out through the space between the block and the frame by the motor mount. Looks like it should go out toward the front? The line has a complex bend at the radiator end, then a foot or so of flex line, then 3 feet back to the tranny where there is a smaller set of bends.

Do I need to take the engine coolant line out of the space between the block and subframe? Which end should it go in first? The old leaky one is still in there, disconnected, just dosen't want to come out. I searched threads but only find cooler upgrade threads, not stock line replacement.

blackout · 10-09-2008, 08:20 AM

Remove the old one and cut the new one in two at a convenient location. Install from both ends and couple together. You will need a proper tubing cutter and maybe a flair tool depending on what type of connector you use. Just make sure you use a tubing cutter and not a hacksaw, so there's no cuttings to get into your fluid... good luck.

Jon Pletcher · 10-09-2008, 08:56 AM

So step one would read "remove engine" to put it in in one piece? Without kinking the old one I can get the back end forward to the frame. Guess I was hoping taking the water hose out would give me enough room to get the rear set of bends wiggled through.. Just hate to cut a perfectly new line to install it.

blackout · 10-09-2008, 09:09 AM

I hear you, but these were probably installed prior to the engine at the factory. Maybe someone else has managed to get that one in somehow...

Jon Pletcher · 10-09-2008, 09:16 AM

Its easy for them to cradle the whole unit, sucks for service. Guess its off for a fitting. Thanks!

NYB · 10-10-2008, 04:38 PM

Jon, I already responded to the other thread that you started on the same subject... but I was able to install a new line uncut. I did cut the old one to get it out, but installed the new one without cutting it.

I don't remember how I did it exactly, but I didn't lift the engine, nor did I drop the tranny. I did it back in 2001, to update the trans cooling system by changing lines from the former trans to OTA cooler to the later (2002 style) trans to OTW cooler in radiator.

Now that I think about it, at some point during my truck's life I removed the starter. I've never had trouble with the starter, so I'm not sure why I removed it, but I did, as I remember marveling at how small the starter motor was for such a high torque engine compared to older starter motors of the 1970's. I even took a picture of the starter (film, so nothing digital to post).

Anyway, now that I think about it, maybe the reason why I removed the starter was to install this line? It was all around the same period of time. Can't think of any other reason why I would have removed it. Maybe that was the secret step that made it possible?