89-91 E-Series 7.3 Diesel 48 Plate Aux. Oil Cooler Installation
1989-91 E-SERIES 7.3L DIESEL 48 PLATE AUXILIARY OIL COOLER INSTALLATION PROCEDURENOTE:
THE HEATER BYPASS SYSTEM SHOULD BE CHECKED AND UPDATED AS REQUIRED TO CONFORM WITH TSB ARTICLE 90-25-17 BEFORE INSTALLATION OF THE AUXILIARY OIL COOLER.
TRANSMISSION AUXILIARY OIL COOLER INSTALLATION (FIGURE 6)
1. Attach auxiliary oil cooler bracket (E3UZ-6K743-B) to radiator/grille support (E3UZ-8182-A needed if vehicle not equipped) using two (2) screw and washer assemblies (55981-S2 1/4-14x1/2 hex washer head tapping). Tighten to 4-8 lb.ft. (5-11 N-m).
2. If the vehicle is equipped with a radiator/grille support, go to Step 3. Attach the radiator/grille support to the radiator core support using two (2) screw and washer assemblies (57030-S2, 1/4-20x.9 hex head lock) and two (2) U-nuts (45263-S101, 1/4-20). Tighten to 7-11 lb.ft. (9.5-15 N-m).
3. Attach auxiliary oil cooler bracket (E7UZ-6K743-A) to the radiator core support using two (2) screw and washer assemblies (55981-S2, 1/4-14x 1/2 hex washer head tapping). Tighten to 4-8 lb.ft. (5-11 N-m).
4. Position the transmission auxiliary cooler on the mounting brackets so the inlet and outlet face the right hand (passenger) side of the vehicle.
5. Attach the cooler to the brackets using two (2) screws (55981-S2 1/4-14x1/2 hex washer head tapping) on the left hand side and two (2) screw and washer assemblies (40927-S8, 1/4-20x1/2 hex head) on the right hand side. Tighten to 4-8 lb.ft. (5-11 N-m).
AUXILIARY COOLER LINE INSTALLATION (FIGURE 7)
1. Trace the rear transmission cooler inlet line to the radiator in-tank cooler outlet fitting.
2. Disconnect the rubber hose from the radiator in-tank cooler outlet fitting.
3. Form the bottom auxiliary cooler line by using 5/16" (7.9 mm) outside diameter steel tubing.
a. Bend the line as required so it goes down the front side of the radiator core support and under the radiator.
b. On the end that is to be connected to the auxiliary cooler, double flare and install fitting (87944-S8).
c. Form a small mushroom on the other end of this line for a rubber hose connection.
4. Install the bottom auxiliary cooler line to the auxiliary cooler.
5. Connect the bottom auxiliary cooler line to the rear transmission cooler inlet line by using the rubber hose disconnected in Step 2. If the rubber hose is too short, use bulk hose (D5AZ-7B093-A) to make a longer section.
6. Form the top auxiliary cooler line by using 5/16" (7.9 mm) outside diameter steel tubing.
a. Bend the line as required so it follows the bottom line down the front side of the radiator core support and under the radiator.
b. On the end that is to be connected to the auxiliary cooler, double flare and install fitting (87944-S8).
c. Form a small mushroom on the other end of this line for a rubber hose connection.
7. Install the top auxiliary cooler line to the auxiliary cooler.
8. Use bulk hose (D5AZ-7B093-A) and hose clamps to connect the top auxiliary cooler line to the radiator in-tank cooler outlet fitting.
9. With the engine running, check the transmission fluid level and top off as required.
10. Check for leaks at all connections.