Since I already had my bumper off to install the TJM T-15, I thought it would
be a good time to install a transmission cooler.
I purchased a Hayden 679 X-HD Transmission oil cooler (11"x11") from AutoZone, part # 238922, for around $56. It came with
almost all the needed hardware, I say almost because I didn't want to replace
the stock hose. I wanted to connect it with the hose supplied with the cooler. The reason will become apparent in the pictures.
Basically it is recessed and would have been hard to get my hand in there to disconnect/connect it.
Installation of the cooler is a cake walk. The challenge lies in getting it in the correct
position. The Hayden connects in series with the 4Runner RETURN line. The Return line
on the 4Runner is on the passenger side.
It is best to do the installation when the truck is cool. I didn't drive mine the day
before the install.
To start off, remove the skid plate.
You will need a pair of vice pliers to clamp the hose going into the radiator. Once you pull the hose out, you will need to plug the exposed
end coming out of the radiator. It may start leaking fluid. Get either a friend to plug it with a finger or some Styrofoam, etc...
Remove center bracket
Position the cooler
I found that removing the center bracket makes it much easier to get the
cooler into the right position.
Then get the cooler into place, as close to the final position
as you can get it. Measure the hoses taking into account the way you're going to
use the coupler to connect them (below) and cut the hoses accordingly.
You need to disconnect one hose in two different spots. The Hayden will
connect between these two spots.
As you can see in the first image above, the leftmost circle marks where the hose
connects to a copper pipe going back to the transmission. It seemed hard for me
to get my hands in there to replace the whole hose without spilling most of the
fluid so I just used the existing hose and got an in-line hose coupler to join
the two hoses. Just don't forget to clamp both sides of the coupler.
Now connect this hose to the cooler and connect the other hose that goes from
the Radiator (Above right image), to the other end of the cooler.
Once all hoses are clamped and ready, it is time to apply those
foam stickers that came with the Hayden. In hindsight it would probably be
better to stick those on before you get the cooler into place.
Now Just feed the zip ties through and insert the locking
plastic nut on the fan side.
There may be other ways to route the hoses to clear the skid
plate, this is the one we found to be best. The top hose should be routed as seen in the images below.
The bottom hose needs to be routed through the
BLUE circle as seen in the images.
Don't forget to clean up those wires.
Once the hoses are in place, zip tie them together and to
something sturdy. I put multiple zip ties in case one broke. When you are sure all is secure, check the ATF level, there may have been some spillage
and/or leaking during the installation. You should also top off
the transmission oil reservoir. Start the vehicle and check for leaks. The last thing you do is put the skid plate back on, paying
extra attention that you do not pinch any of the hoses.
This site and all original materials contained herein are Copyright 1999 - 2013 by OutdoorWire, Inc. -- All Rights Reserved.
You may link freely to this site, but no further use is allowed without the express written permission of the owner of this material.
All corporate trademarks are the property of their respective owners.
This publication and OutdoorWire, Inc. assume no liability for your use of the material contained within this site.
OutdoorWire, 4x4Wire, SUVWire, JeepWire, MUIRNet-News, and 4x4Voice are all trademarks and publications of OutdoorWire, Inc.