Section 1 - Oil Cooler
SECTION 1Installation Procedure For
Oil Cooler Kit #1, Air-cooled Transmission (P/N 04006-10135)
Step 1 Assemble the air-cooled oil cooler using the following procedure:
A. Assemble the two unions, using the supplied O-rings, to the oil cooler, and torque the unions to 16 ft.lbs. (222 kg-cm)
Figure 1 - Front View:
Figure 2 - Side View:
Note: See reference #1 on Figures 1 & 2
B. Assemble the oil cooler bracket to the oil cooler with the bolts, stays, and nuts supplied, and torque the bolts to 9 ft.lbs. (120 kg-cm).
Note: See reference #2 on Figures 1 & 2
C. Install the inlet and outlet tubes to the oil cooler and hand tighten the unions.
Note: See reference #4 on Figures 1 & 2
D. Install cooler line clamp and temporarily tighten.
Note: See reference #5 on Figures 1 & 2
E. Install the 330 mm length of hose on the outlet tube and secure with a hose clamp.
Note: See reference #3 on Figure 2
F. Install the 270 mm length of hose (has a white paint mark) on the inlet tube and secure with a hose clamp.
Note: See reference #3 on Figure 2
Step 2 Remove drain plug from transmission oil pan and drain transmission fluid.
Step 3 Remove front bumper and grille assemblies.
Step 4 Check the vehicle you are working on to see if it is equipped with air
conditioning. If equipped with Toyota A/C, continue with Step 4, if not go on to Step 5.
A. As noted on the application chart on page 1, you will need the following additional parts
Liquid tube (P/N 88716-89151) Cooler Plate (P/N 88892-89113) Screw (P/N 93567-55014)
B. Replace the old liquid tube with the new unit.
Figure 3:
C. Install the cooler plate to the A/C condenser as shown in Figure 3.
Figure 4:
D. Using the new screws, connect, and clamp the liquid tube as shown in Figure 4.
FIGURE 5 - RADIATOR UPPER SUPPORT HOLE POSITION:
Step 5
A. Using Figure 5 as a guide, drill two 9 mm holes in the radiator upper support.
Note: If holes already exist, this step is not necessary.
FIGURE 6 - RADIATOR LOWER SUPPORT AND FRONT CROSSMEMBER HOLE POSITION:
B. Using Figure 6 as a guide, drill two 9 mm holes in the radiator front crossmember.
Note: If holes already exist, this stop is not necessary.
Figure 7:
Step 6 Mount the oil cooler assembly (See Figure 7)
Figure 8:
A. If the 9 mm holes were present, weld nuts should be present behind the crossmembers. If the weld nuts are not present, or you had to drill the holes, you will have to gain access to the back side of the crossmember to use the supplied bolt and nuts. (See Figure 8)
Figure 1 - Front View:
Figure 2 - Side View:
B. A clearance of at least .5 mm or more between the oil coolor and condenser should be maintained so that the oil cooler stays will not contact the liquid tube.
C. Once the cooler assembly is installed and secure, tighten the inlet and outlet tube unions seen on Figure 1 & 2.
D. Tighten the tube clamp seen on Figure 1 & 2. Reference #5.
Step 7 If the vehicle was built:
thru : Jan. 1986 ending VIN: RN55-7004790 (cab & chassis) RN75-0004786 (cab & chassis)
Valve body Kit #2 (P/N 04006-10235), inlet cooler tube kit (P/N 32921-35120); and outlet cooler tube kit (P/N 32922-35140) installation is required. Go to Sec. 2 Installation of Valve Body Kit #2.
NOTE: If the vehicle was built after the production information listed in Step 7, continue with Step 8.
Figure 9:
Step 8 Connect the new oil to air cooler in series with the factory oil to
water cooler by removing the OEM outlet hose and connecting the new hoses from the oil to air cooler to the factory tubing as shown in Figure 9.
Step 9 Final assembly
A. Install radiator grille, making certain that there is no interference between the grille and the oil cooler lines.
Figure 10:
B. If interference does exist, file the radiator grille to, provide clearance. (See Figure 10)
C. Complete final installation of the grille and front bumper.
D. Fill transmission with new Dexron II ATF fluid (will require approximately 2 liters).
E. Start engine and check all connections for leaks.
F. After transmission has reached operating temperature, check fluid level and add as necessary.