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Unread 08-21-2010, 08:00 PM   #1
Thunderstrike
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Transmission cooler and Shrockworks Midwidth Bumper Install

Disconnecting transmission return line. Instead of cutting in the middle of rubber hose and use a restricting inline coupler, I decided to remove the darn thing to connect directly to hard line.


Flushing transmission fluid. Using a gallon jug marked with 3 quarts line; drained 4 times, and filled in new TATF-4 fluids.


B&M 70268 Transmission Cooler lines hooked up


B&M 70268 Transmission Cooler installed. Painted mounting hardware black.
Also, installed IPF H4 headdlights.


Installed Shrockworks Midwidth Bumper.


Will post final mod pictures tomorrow (bug screen and Warn winch).

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2009 JK Rubicon (Former Daily Driver); 2014 VW Jetta GLI Autobahn w NAV.
Auto, Power, Remote Start, Towing Package, MyGig Navigation with Lockpick, Rear View Camera, B&M 70268 Transmission Cooler, Aeroforce Interceptor, Valentine 1, Tub Sound-Deadened with Raamat and Ensolite, Hard Top Heat Insulated with 1/2" Styrofoam Insulation, Bilstein Shocks Front & Rear, PIAA Dual Horns, IPF 920H4 Headlights.
Protection: Skid Row Engine Skid, Lower Control Arm skid & Evaporator Skid; Rock Hard Gas Tank Skid; Warn Stainless Steel Differential Skid Front & Rear.
Recovery Gear: Warn 9.5Ti Winch, 11,000# Pull-Pal.
Communication: Uniden 520XL CB, Diesel External Speaker, 3' FireStik Whip.
Shrockworks Mid-width Front Bumper with Warn 9.5Ti Winch -- Ordered 7/17/2009; Bumper Received 12/4/2009.
1" Coil Spacer Front & 1/2" Coil Spacer Rear restored OEM Rake.
4x4 Trips:
Moab - 4/2006, 5/2008, 4/2009, 5/2011, 4/2013
Ouray - 8/2007
Rubicon - 9/2008
Gone, but not forgotten: 2004 TJ, 1999 Audi A4, 1992 VW Jetta GL 5 Speed

Last edited by Thunderstrike; 08-22-2010 at 05:18 PM..
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Unread 08-22-2010, 07:09 AM   #2
Dronac
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How much fluid comes out when you disconnect the lines? Also, how did you flush the tranny into the milkjug? Iv never seen that method before, and it looks much easier then dropping the pan three times.
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2008 Jeep JK X: auto trans, 3.73 gears, D44 rear, D30 front
Mods: 2'' Rusty's coil lift, Superchips 93 octane tune, Cobra 75 CB radio, 33'' Duratrac's, onboard air compressor
My Build Thread! ---> http://www.jeepforum.com/forum/f96/dronacs-build-thread-1104134/
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Unread 08-22-2010, 07:51 AM   #3
Thunderstrike
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When I disconnected OEM tranny hose, only teaspoon full of fluid came out, so plastic bag-covered cardboard box catched all the drips and splashes.

Then I ran a short hose to OEM aluminum return line to a milk jug. I had my wife crank the engine and let it run and watch tranny fluid pour into the jug. When it reached just below the 3 quarts line I told my wife to shut off the engine. With a slight delay in shutting off engine the fluid level will reach the 3 quarts line.

Then I would put in 3 quarts of ATF-4 into the transmission dipstick fill tube. Repeat the process three more times. Check the dipstick, and fill to correct level. Hook up tranny lines and check for any leakage.

With this flush method, one is replacing fluids up in torque converter as well as in the pan. Dropping the plan would only replace fluid in the pan. The question is -- if one flushes often would the filter need to be replaced at 60,000 miles? Guess I could replace it at much later mileage. Would be nice for someone who had replaced filter to charm in on this thought.
__________________
2009 JK Rubicon (Former Daily Driver); 2014 VW Jetta GLI Autobahn w NAV.
Auto, Power, Remote Start, Towing Package, MyGig Navigation with Lockpick, Rear View Camera, B&M 70268 Transmission Cooler, Aeroforce Interceptor, Valentine 1, Tub Sound-Deadened with Raamat and Ensolite, Hard Top Heat Insulated with 1/2" Styrofoam Insulation, Bilstein Shocks Front & Rear, PIAA Dual Horns, IPF 920H4 Headlights.
Protection: Skid Row Engine Skid, Lower Control Arm skid & Evaporator Skid; Rock Hard Gas Tank Skid; Warn Stainless Steel Differential Skid Front & Rear.
Recovery Gear: Warn 9.5Ti Winch, 11,000# Pull-Pal.
Communication: Uniden 520XL CB, Diesel External Speaker, 3' FireStik Whip.
Shrockworks Mid-width Front Bumper with Warn 9.5Ti Winch -- Ordered 7/17/2009; Bumper Received 12/4/2009.
1" Coil Spacer Front & 1/2" Coil Spacer Rear restored OEM Rake.
4x4 Trips:
Moab - 4/2006, 5/2008, 4/2009, 5/2011, 4/2013
Ouray - 8/2007
Rubicon - 9/2008
Gone, but not forgotten: 2004 TJ, 1999 Audi A4, 1992 VW Jetta GL 5 Speed

Last edited by Thunderstrike; 08-22-2010 at 08:03 AM..
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Unread 08-22-2010, 08:20 AM   #4
JIMBOX
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Looks like a great job-

Just remember that the top line is the tranny return line !!

JIMBO
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Unread 08-22-2010, 10:19 AM   #5
Dronac
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Quote:
Originally Posted by Thunderstrike View Post
When I disconnected OEM tranny hose, only teaspoon full of fluid came out, so plastic bag-covered cardboard box catched all the drips and splashes.

Then I ran a short hose to OEM aluminum return line to a milk jug. I had my wife crank the engine and let it run and watch tranny fluid pour into the jug. When it reached just below the 3 quarts line I told my wife to shut off the engine. With a slight delay in shutting off engine the fluid level will reach the 3 quarts line.

Then I would put in 3 quarts of ATF-4 into the transmission dipstick fill tube. Repeat the process three more times. Check the dipstick, and fill to correct level. Hook up tranny lines and check for any leakage.

With this flush method, one is replacing fluids up in torque converter as well as in the pan. Dropping the plan would only replace fluid in the pan. The question is -- if one flushes often would the filter need to be replaced at 60,000 miles? Guess I could replace it at much later mileage. Would be nice for someone who had replaced filter to charm in on this thought.
Forgive my lack of understanding transmissions, but if all that fluid is coming out, and non is going right back in, doesn't that let the ATF level get low, thus possibly doing damage since it is running?
__________________
2008 Jeep JK X: auto trans, 3.73 gears, D44 rear, D30 front
Mods: 2'' Rusty's coil lift, Superchips 93 octane tune, Cobra 75 CB radio, 33'' Duratrac's, onboard air compressor
My Build Thread! ---> http://www.jeepforum.com/forum/f96/dronacs-build-thread-1104134/

Last edited by Dronac; 08-22-2010 at 11:12 AM..
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Unread 08-22-2010, 01:36 PM   #6
Thunderstrike
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Quote:
Originally Posted by Dronac View Post
Forgive my lack of understanding transmissions, but if all that fluid is coming out, and non is going right back in, doesn't that let the ATF level get low, thus possibly doing damage since it is running?
I drain 3 quarts, stop engine, refill 3 quarts; at this point it's filled to normal level. Then, repeat the process 3 more times, thus replacing 12 quarts of old fluid with new.
__________________
2009 JK Rubicon (Former Daily Driver); 2014 VW Jetta GLI Autobahn w NAV.
Auto, Power, Remote Start, Towing Package, MyGig Navigation with Lockpick, Rear View Camera, B&M 70268 Transmission Cooler, Aeroforce Interceptor, Valentine 1, Tub Sound-Deadened with Raamat and Ensolite, Hard Top Heat Insulated with 1/2" Styrofoam Insulation, Bilstein Shocks Front & Rear, PIAA Dual Horns, IPF 920H4 Headlights.
Protection: Skid Row Engine Skid, Lower Control Arm skid & Evaporator Skid; Rock Hard Gas Tank Skid; Warn Stainless Steel Differential Skid Front & Rear.
Recovery Gear: Warn 9.5Ti Winch, 11,000# Pull-Pal.
Communication: Uniden 520XL CB, Diesel External Speaker, 3' FireStik Whip.
Shrockworks Mid-width Front Bumper with Warn 9.5Ti Winch -- Ordered 7/17/2009; Bumper Received 12/4/2009.
1" Coil Spacer Front & 1/2" Coil Spacer Rear restored OEM Rake.
4x4 Trips:
Moab - 4/2006, 5/2008, 4/2009, 5/2011, 4/2013
Ouray - 8/2007
Rubicon - 9/2008
Gone, but not forgotten: 2004 TJ, 1999 Audi A4, 1992 VW Jetta GL 5 Speed

Last edited by Thunderstrike; 08-22-2010 at 01:48 PM..
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Unread 08-22-2010, 01:36 PM   #7
Thunderstrike
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With black bug screen installed, can't see the tranny cooler.

I drilled three small holes on the vertical plastic housing by each headlight. I used tie wrap to tie up bug screens on both side with tension. I slit four holes at the bottom for grill mounting stubs. Did likewise on the top as I installed quick snap-ins at the top of the grill.

Finished install.
__________________
2009 JK Rubicon (Former Daily Driver); 2014 VW Jetta GLI Autobahn w NAV.
Auto, Power, Remote Start, Towing Package, MyGig Navigation with Lockpick, Rear View Camera, B&M 70268 Transmission Cooler, Aeroforce Interceptor, Valentine 1, Tub Sound-Deadened with Raamat and Ensolite, Hard Top Heat Insulated with 1/2" Styrofoam Insulation, Bilstein Shocks Front & Rear, PIAA Dual Horns, IPF 920H4 Headlights.
Protection: Skid Row Engine Skid, Lower Control Arm skid & Evaporator Skid; Rock Hard Gas Tank Skid; Warn Stainless Steel Differential Skid Front & Rear.
Recovery Gear: Warn 9.5Ti Winch, 11,000# Pull-Pal.
Communication: Uniden 520XL CB, Diesel External Speaker, 3' FireStik Whip.
Shrockworks Mid-width Front Bumper with Warn 9.5Ti Winch -- Ordered 7/17/2009; Bumper Received 12/4/2009.
1" Coil Spacer Front & 1/2" Coil Spacer Rear restored OEM Rake.
4x4 Trips:
Moab - 4/2006, 5/2008, 4/2009, 5/2011, 4/2013
Ouray - 8/2007
Rubicon - 9/2008
Gone, but not forgotten: 2004 TJ, 1999 Audi A4, 1992 VW Jetta GL 5 Speed

Last edited by Thunderstrike; 08-22-2010 at 06:10 PM..
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Unread 08-22-2010, 05:18 PM   #8
Vin
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Is the bug screen DIY or a kit? If a kit, which one?
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Unread 08-22-2010, 05:23 PM   #9
Thunderstrike
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Quote:
Originally Posted by Vin View Post
Is the bug screen DIY or a kit? If a kit, which one?
DIY. Got the material from Lowes.
__________________
2009 JK Rubicon (Former Daily Driver); 2014 VW Jetta GLI Autobahn w NAV.
Auto, Power, Remote Start, Towing Package, MyGig Navigation with Lockpick, Rear View Camera, B&M 70268 Transmission Cooler, Aeroforce Interceptor, Valentine 1, Tub Sound-Deadened with Raamat and Ensolite, Hard Top Heat Insulated with 1/2" Styrofoam Insulation, Bilstein Shocks Front & Rear, PIAA Dual Horns, IPF 920H4 Headlights.
Protection: Skid Row Engine Skid, Lower Control Arm skid & Evaporator Skid; Rock Hard Gas Tank Skid; Warn Stainless Steel Differential Skid Front & Rear.
Recovery Gear: Warn 9.5Ti Winch, 11,000# Pull-Pal.
Communication: Uniden 520XL CB, Diesel External Speaker, 3' FireStik Whip.
Shrockworks Mid-width Front Bumper with Warn 9.5Ti Winch -- Ordered 7/17/2009; Bumper Received 12/4/2009.
1" Coil Spacer Front & 1/2" Coil Spacer Rear restored OEM Rake.
4x4 Trips:
Moab - 4/2006, 5/2008, 4/2009, 5/2011, 4/2013
Ouray - 8/2007
Rubicon - 9/2008
Gone, but not forgotten: 2004 TJ, 1999 Audi A4, 1992 VW Jetta GL 5 Speed
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Unread 08-22-2010, 05:30 PM   #10
Vin
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Quote:
Originally Posted by Thunderstrike View Post
DIY. Got the material from Lowes.
In that case, VERY nicely done.

On a side note in your last pic, why is the D/S wheel turned while the P/S looks strait?
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Unread 08-22-2010, 05:34 PM   #11
JLC08JK
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Nice job Thunderstrike
I like that bumper, it's clean and simple!

P.S. link to this thread added to F.A.Q.
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Unread 08-22-2010, 05:43 PM   #12
Thunderstrike
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Quote:
Originally Posted by Vin View Post
In that case, VERY nicely done.

On a side note in your last pic, why is the D/S wheel turned while the P/S looks strait?
It's the camera lens, having some wide angle affect.
__________________
2009 JK Rubicon (Former Daily Driver); 2014 VW Jetta GLI Autobahn w NAV.
Auto, Power, Remote Start, Towing Package, MyGig Navigation with Lockpick, Rear View Camera, B&M 70268 Transmission Cooler, Aeroforce Interceptor, Valentine 1, Tub Sound-Deadened with Raamat and Ensolite, Hard Top Heat Insulated with 1/2" Styrofoam Insulation, Bilstein Shocks Front & Rear, PIAA Dual Horns, IPF 920H4 Headlights.
Protection: Skid Row Engine Skid, Lower Control Arm skid & Evaporator Skid; Rock Hard Gas Tank Skid; Warn Stainless Steel Differential Skid Front & Rear.
Recovery Gear: Warn 9.5Ti Winch, 11,000# Pull-Pal.
Communication: Uniden 520XL CB, Diesel External Speaker, 3' FireStik Whip.
Shrockworks Mid-width Front Bumper with Warn 9.5Ti Winch -- Ordered 7/17/2009; Bumper Received 12/4/2009.
1" Coil Spacer Front & 1/2" Coil Spacer Rear restored OEM Rake.
4x4 Trips:
Moab - 4/2006, 5/2008, 4/2009, 5/2011, 4/2013
Ouray - 8/2007
Rubicon - 9/2008
Gone, but not forgotten: 2004 TJ, 1999 Audi A4, 1992 VW Jetta GL 5 Speed
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Unread 08-22-2010, 06:04 PM   #13
Thunderstrike
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Installed Superwinch Quick Connect.

__________________
2009 JK Rubicon (Former Daily Driver); 2014 VW Jetta GLI Autobahn w NAV.
Auto, Power, Remote Start, Towing Package, MyGig Navigation with Lockpick, Rear View Camera, B&M 70268 Transmission Cooler, Aeroforce Interceptor, Valentine 1, Tub Sound-Deadened with Raamat and Ensolite, Hard Top Heat Insulated with 1/2" Styrofoam Insulation, Bilstein Shocks Front & Rear, PIAA Dual Horns, IPF 920H4 Headlights.
Protection: Skid Row Engine Skid, Lower Control Arm skid & Evaporator Skid; Rock Hard Gas Tank Skid; Warn Stainless Steel Differential Skid Front & Rear.
Recovery Gear: Warn 9.5Ti Winch, 11,000# Pull-Pal.
Communication: Uniden 520XL CB, Diesel External Speaker, 3' FireStik Whip.
Shrockworks Mid-width Front Bumper with Warn 9.5Ti Winch -- Ordered 7/17/2009; Bumper Received 12/4/2009.
1" Coil Spacer Front & 1/2" Coil Spacer Rear restored OEM Rake.
4x4 Trips:
Moab - 4/2006, 5/2008, 4/2009, 5/2011, 4/2013
Ouray - 8/2007
Rubicon - 9/2008
Gone, but not forgotten: 2004 TJ, 1999 Audi A4, 1992 VW Jetta GL 5 Speed
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Unread 05-11-2012, 02:37 PM   #14
TDmaster
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Quote:
Originally Posted by Thunderstrike View Post
Disconnecting transmission return line. Instead of cutting in the middle of rubber hose and use a restricting inline coupler, I decided to remove the darn thing to connect directly to hard line.
What did you use to cut the metal crimps over the hoses that attach to the aluminum tubing? - A dremmel? Just curious, because I'm considering the same thing.

FYI: On my transmission (42RLE), the line going to the far back of the gear box, just over the oil pan, is the return line. The line going in towards the top of gear box and closer to the engine is the output line going from the tranny to the stock integrated A/C condenser/Transmission Cooler.

Using that rear line as a reference for the return line, it appears to be the bottom line (not the one you cut) in your picture looking from the top down behind the radiator. Can mine be crossed?
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Unread 05-11-2012, 02:51 PM   #15
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Quote:
Originally Posted by TDmaster View Post
What did you use to cut the metal crimps over the hoses that attach to the aluminum tubing? - A dremmel? Just curious, because I'm considering the same thing.

FYI: On my transmission (42RLE), the line going to the far back of the gear box, just over the oil pan, is the return line. The line going in towards the top of gear box and closer to the engine is the output line going from the tranny to the stock integrated A/C condenser/Transmission Cooler.

Using that rear line as a reference for the return line, it appears to be the bottom line (not the one you cut) in your picture looking from the top down behind the radiator. Can mine be crossed?
I used a dremmel to cut through the crimps when I was experimenting with different fittings on the lines.

Looking at some tech data on the 42RLE, it shows the upper line on the side of the transmission is return from the cooler.
The lower line on the side of the transmission is output to the cooler.

The top line in the picture above is the line that carries fluid back to the transmission. That's the one you want to tap into for an aux cooler. Using that line, the fluid will exit the stock cooler, go through the aux cooler, and from there go back to the transmission.
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