I was asked, by Duggy, to put together a how-to document on fitting a trans cooler. There are different coolers available and more than one way to fit them. I therefore have detailed below, how I fitted one to my 4.0 EL GLi.
The Cooler that I fitted was a Davies Craig Universal Fit cooler, model number 676. This cooler is ment for cars of "up to 2.0 litre" capacity. However, it is the same design "Hydra-Cool" cooler as the model 682 cooler, ment for "Ford EF/EL 6cyl & V8". It also happens to be twice
the size of the model 682. If you wanted a bigger cooler you could get the model 677 or model 678 coolers.
So, what will you need?
2- a Falcon.
3- a cooler kit.
4- a friend/mate/spouse/etc to help you, at the appropriate point.
5- a set of car ramps
6- a tool set.
7- a pipe cutter.
8- an extra length of 3/8" hydraulic hose.
9- a Gregory's Manual for your model Falcon.
10- about four to five hours to do the job.
11- a box of Band-aids!
To start with. you may wish to make a special tool. Part of the procedure, involves removing the front bumper. On EF/EL Falcons, you will need to undo a 1/2" / 13mm nut, located under the front indicators. This nut is hard to get at. You have two options. One is to do what I did and use a small tube spanner in a larger one, to create the necessary length. The other, is to go down to Supa-Cheap and buy a $1 spanner and cut it in half.
OK. Are we ready to start?
Too bad, coz we're gunna!
BTW, if in doubt, please refer to the pictures for a visual reference.
Drive your car onto the car ramps. Open up your Gregory's manual to the chapter called "Body". In it you will find instructions on how to remove the front bumper and under-tray. Follow these instructions and you will be half way there. This is where the friend/mate/spouse/etc comes in. You will need their help to lift the bumper off and back on again later. You will also need your special tool for this as well. I suggest using an air hose to thoroughly clean any dead bugs from the front of the A/C condensor, while you have free access to it. Also, I took the opportunity to cut and fit some fly wire to the metal grill in the mouth of the bumper.
look under the front of the car and you should see the two trans cooler pipes running across the front under the radiator. On the EF/EL falcon, you will see a brass joint in the middle of it. Before touching it, make sure the pipes are clean. A rag moistenned with petrol or kero will do. You will need a 19mm and a 17mm spanner to undo this joint.
With the joint undone pull the section of pipe that goes to the radiator down, gently. The pipe is soft enough, to bend down. You will not need to bend it down very far. Just enough to get the pipe cutter on it. Now using the pipe cutter, cut the pipe about 50mm up from the kink, towards the radiator tank. This will give you a short piece of pipe with the brass fitting and a kink in it. At this point, you can gently bend the remaining pipe section back into place. Now re-attach the piece using the brass fittings and make sure you offset this piece, slightly, so that the two cut ends don't point back at each other. This will allow the hoses to pass by each other. Congratulations, the hardest part is now done.
Now you need to run your hoses. I purchased an extra length of hose from Pirtek for the job. The cooler kit comes with a 1m length, which is not nearly enough. Run a hose through each bumper mounting point, down the chassis, as per the photos. From the engine compartment side, pull each hose through and down towards where the pipe was cut. Put a hose clamp on each hose and slip them (the hoses) onto the pipes. Position and tighten up the hose clamps. Using a cable tie, tie the two hoses together, where they run next to each other. Then, using another cable tie, tie the hose coming from the passenger side to the other trans cooler pipe. This will keep it well away from the A/C pump and serpentine belt.
Hose through chassis rail on passenger side. Note: white 65mm PVC airbox feed at right side of photo.
Hose through chassis rail on drivers side
You must now mount the cooler in front of the A/C condensor. I filed out two holes on my cooler in order to use two existing bolts on the bar that carries the power steering cooler pipe. I then undid the nut on the P/S cooler pipe and got an identicle nut for the other bolt. Using three large nuts as spacers, on the lower bolt, I fitted the cooler and put the two nuts back on the two bolts. I also put a spring washer on the lower bolt. The upper bolt tightens on a rubber block and shouldn't need a washer. I also put a cable tie through the top of the cooler at the other end and around the P/S cooler pipe. You may wish to mount your cooler a different way. The choice is yours.
Now it's time to finish off the fitment. Take each hose, one at a time and run it across to the cooler. Then cut it to length. Take the free ends of the two hoses and slide a hose clamp on each. Remove the dust protectors from the cooler and push each hose on to the cooler spouts. You may find that a coating of spit, on the "barb" will help the hoses to slide on. Now position and tighten up the hose clamps (below the barbs on the spouts). At this point, I would suggest that it is a good idea to double check all your fittings and clamps. Now, start your car up and have a good look see at everything. If you have had your car running before you started, you will find that the cooler and pipes/hoses will heat up very fast.
Put the bumper back onto the car. Refer to your Gregory's manual on the procedure. Now, check the fluid level in your tranny. You shouldn't need to top it up, as the fitting procedure would have resulted in the loss of only a few spoonfuls of fluid.
Take your pride and joy for a spin, Coz you are finished!!!
I hope that this helps anyone wanting to fit a trans cooler.
Best of luck.