C. Replace Engine-Mounted Trans. Cooler & Cooler Line
NOTE:The following procedure is only required if the engine-mounted transmission cooler requires replacement per the inspection in Section "A."
Very few vehicles are expected to require transmission cooler replacement
1. Disconnect the negative battery cable from each battery.
2. Open the radiator drain plug and drain the coolant from the radiator into an appropriate container. Save the coolant for later re-use.
WARNING:
Do not loosen the radiator drain plug with the system hot and under pressure. Serious burns from coolant can occur.
3. If the engine coolant is contaminated with transmission fluid, the cooling system must be flushed to remove the contamination. Follow the procedure in Section 7 - Cooling in the 2004 DR Service Manual to flush the cooling system.
4. Raise the vehicle on an appropriate hoist.
5. Remove the three (3) starter mounting bolts (Figure 3).
6. Move the starter forward far enough to clear the bell housing, then tilt the nose of the starter downwards and lower the starter enough to remove the nuts that secure the wiring harness to the starter. Remove the starter from the engine and set it aside.
7. Disconnect the transmission cooler line from the transmission (Figure 4).
8. If the transmission fluid is contaminated with engine coolant, the rest of the cooler system must be flushed and the transmission must be rebuilt or replaced. Follow the procedure in Section 21 - Transmission in the 2004 DR Service Manual and Warranty Rebuild/Replace policies to repair the transmission if the fluid is contaminated.
IMPORTANT:
When rebuilding the transmission, all friction material, rubber-based seals and the torque converter must be replaced. In addition, the transmission cooler lines and radiator mounted cooler must be flushed.
9. Lower the vehicle to a working level.
10. Remove the left front wheel and tire assembly.
11. Remove the left front wheel well inner fender shield.
12. Disconnect the transmission cooler line from the engine-mounted transmission cooler (Figure 4).
13. Disconnect the transmission cooler outlet line from the engine-mounted transmission cooler (Figure 4).
14. Disconnect the coolant inlet and outlet hoses from the engine-mounted transmission cooler (Figure 5).
15. Remove the wiring harness clip from the cooler bracket.
16. Remove the three (3) transmission cooler bracket fasteners (Figure 5) and then remove the cooler and bracket from the engine as an assembly.
17. Install the new transmission cooler and bracket assembly (Figure 5). Hand start the three (3) mounting fasteners only.
18. Tighten the lower cooler bracket-to-cylinder block mounting bolt to 57 ft-lbs (77 N.m).
19. Tighten the upper cooler bracket-to-cylinder block mounting bolt to 18 ft-lbs (24 N.m).
20. Tighten the lower cooler bracket-to-transmission adapter mounting bolt to 18 ft-lbs (24 N.m).
21. Connect the coolant inlet and outlet hoses to the transmission cooler. Make sure that the hose clamps are installed inboard of the upset bead.
22 Connect the transmission cooler outlet line to the transmission cooler. Tighten the fitting to 280 in-lbs (32 N.m).
23. Connect the wiring harness clip to the cooler bracket.
24. Install the left front inner fender shield.
25. Install the left front wheel and tire assembly. Tighten the lug nuts to 135 ft-lbs (180 Nm).
26. Raise the vehicle fully.
27. Connect the new transmission cooler line to the transmission cooler (Figure 4). Hand-start the fitting but do not tighten.
28. Connect the transmission cooler line to the transmission (Figure 4). Hand-start the fitting but do not tighten.
29. Check the alignment of the new cooler line (Figure 6). Make sure that the hose portion of the line is not contorted or twisted as this can cause the hose to fail.
30. Keeping the cooler line aligned properly, tighten the cooler line-to-transmission fitting to 280 in-lbs (32 N.m).
31. Keeping the cooler line aligned properly, tighten the cooler line-to-cooler fitting to 280 in-lbs (32 N.m).
32. Check the alignment of the new cooler line. Make sure that the hose portion of the line is not contorted or twisted. If the hose portion is twisted or contorted, loosen both cooler line fittings and repeat Steps 29-31.
33. Position the starter onto the engine.
34. Install the starter wiring. Tighten the large battery cable nut to 120 in-lbs (14 N.m). Tighten the smaller starter solenoid nut to 55 in-lbs (6 N.m).
35. Position the starter into the bell housing (Figure 3). Install the three (3) starter mounting bolts and then tighten the bolts to 32 ft-lbs (43 N.m).
36. Lower the vehicle.
37. Connect both negative battery cables.
38. Fill the engine cooling system with coolant. Re-use the original coolant if it was not contaminated.
39. Start the engine and check for any leaks.
40. Check the transmission fluid level and adjust if necessary.