Repair Procedure

This bulletin involves installing a transmission fluid auxiliary cooler.

NOTE:
ONLY INSTALL THE TRANSMISSION FLUID AUXILIARY COOLER AFTER THE EXISTING TRANSMISSION OIL COOLER AND TRANSMISSION HAVE BEEN THROUGHLY FLUSHED.

1. Release the hood latch and open the hood.

2. Recover the A/C system refrigerant.

3. Remove the bolts (one per side) attaching the fascia to the headlamp mounting panel at each side of the grille.

4. Raise the vehicle on an appropriate hoist.

5. Remove the front tire/wheel assemblies.

6. Remove the screws attaching the front wheelhouse splash shields to gain access to the bolts attaching the front fascia to the fenders.

7. Remove the bolts (2 each side) attaching the front fascia to the bottom of the fenders.

8. Remove the 6 bolts attaching the front fascia to the bottom of the radiator closure panel.

9. Disconnect the fog lamp wiring connectors, if equipped.

10. Separate the front fascia from the vehicle.

11. Lower the vehicle to an appropriate height.

12. Remove the refrigerant line from the filter-drier to condenser.

13. Disconnect the compressor to condenser refrigerant line from the condenser.

14. Mark the position of the hood latch, for re-installation purposes, then remove the latch attaching bolts and set the latch aside.

15. Remove the (4) condenser mounting bolts.

16. Remove the condenser(s) from the vehicle.

17. Install a closed cell foam pad to the flush side of both mounting flanges of the transmission auxiliary fluid cooler so they are between the outboard holes.

18. For Standard A/C Equipped Vehicles, position the transmission auxiliary fluid cooler with hose nipples pointing down to the face of the condenser so the edge of the cooler is flush with the drivers side edge of the condenser core and the top mounting flange holes of the cooler are aligned with the 7th row (from the top) of fins in the condenser core.

For Dual A/C Equipped Vehicles, position the transmission auxiliary fluid cooler with hose nipples pointing up to the face of the condenser so the edge of the cooler is flush with the drivers side edge of the condenser core and the bottom mounting flange holes of the cooler are aligned with the 2nd (from the bottom) row of fins in the condenser core.

19. Insert mounting straps from the radiator side of the condenser through the fins and into the two outboard holes in the top flange of the cooler. Loosely install locks on the mounting straps.

20. Insert mounting straps from the radiator side of the condenser through the fins and into the two outboard holes in the bottom flange of the cooler. Install locks on the bottom mounting straps and tighten all the locks against the cooler mounting flanges. Cut the excess mounting strap material off.





21. For Standard A/C Equipped Vehicles, install a vertical seal to the face of the radiator side of both main condenser end tanks, Figure 1. Rear A/C equipped vehicles already have these seals installed.

22. Install the condenser/auxiliary cooler assembly. Torque the condenser to radiator attaching bolts to 4-6 Nm (35-55 in. lbs.).

23. Install the upper condenser to radiator air seal. Insure the top surface of the condenser is clean, then remove the backing from the adhesive strip on the air seal and attach the seal to the top surface of the condenser so the seal covers the gap between the condenser and radiator.

24. Install the hood latch aligning it with the marks made in step 14.

25. Connect the refrigerant lines. Torque the fasteners to 19-21 Nm (170-190 in. lbs.).

26. Evacuate the A/C system. Continue evacuation for 45 minutes after the suction gauge reads -88 kPa (-26 in. Hg).

27. Remove the air inlet resonator and air cleaner.

28. For Trailer Tow (AHT) Equipped Vehicles, remove and discard both transmission fluid cooler hoses from the transmission to radiator. Install formed hose, p/n 04682455, and clamps, p/n 06032839, to the outboard port of the transmission and the lower nipple of the radiator.

For NON-Trailer Tow Equipped Vehicles, remove the tape securing the transmission fluid cooler hoses together. Remove and discard the upper transmission fluid cooler hose and clamps.





29. Pierce/Cut two "X"'s in the driver side radiator side air seal for the 5/16 in. fluid hoses to pass through, Figure 2.

30. Cut the bulk 5/16 in. fluid hose into three pieces of the following lengths: 76 cm (30 in.), 102 cm (40 in.) and 66 cm (26 in.).

31. Install the 76 cm (30 in.) hose and a clamp to the outboard fitting of the auxiliary cooler. Route the hose through one of the holes cut (step 29) in the driver side radiator side air seal and install the hose and clamp to the top radiator transmission fluid hose fitting. Torque the clamps to 2 Nm (16-20 in. lbs.).

32. Install the 102 cm (40 in.) hose and a clamp to the inboard fitting of the auxiliary cooler. Route the hose through the other hole cut (step 29) in the driver side radiator side air seal and install the hose and clamp to the inboard nipple on the transmission. Torque the clamps to 2 Nm (16-20 in. lbs.).

33. If the vehicle is equipped with the optional trailer tow package (sales code AHT), remove and discard the auxiliary transmission fluid cooler hose and line assembly from the fan shroud. Install the 66 cm (26 in.) hose and clamps between the transmission fluid cooler fittings on the passenger side of the radiator (this in-tank cooler is not used with the addition of the air to fluid auxiliary cooler). Torque the clamps to 2 Nm (16-20 in. lbs.).

34. Install the air inlet resonator and the air cleaner housing.

35. Charge the A/C system with R134a refrigerant using the procedure outlined and the quantity specified in the appropriate service manual.

36. Start the engine and check for leaks at the transmission fluid lines, correct as necessary.

37. With the transmission at normal operating temperature check the transmission fluid level. If fluid needs to be added use only Mopar ATF+2 Type 7176 (p/n 04798233).

38. Install the front fascia.

39. Install the front tire/wheel assemblies.