Oil Cooler Hose/Pipe Replacement Front

Tools Required

1. Position the front wheels straight ahead, then remove the ignition key to lock the steering column.

Caution: Unless directed otherwise, the ignition and start switch must be in the OFF or LOCK position, and all electrical loads must be OFF before servicing any electrical component. Disconnect the negative battery cable to prevent an electrical spark should a tool or equipment come in contact with an exposed electrical terminal. Failure to follow these precautions may result in personal injury and/or damage to the vehicle or its components.

2. Disconnect the negative battery cable.
3. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
4. Have a drain pan ready to catch fluid.
5. If equipped with the flared fitting design, disconnect the transmission oil cooler (TOC) front upper pipe fitting from the radiator, then cap the pipe fitting and plug the TOC fitting to prevent contamination.



6. If equipped with the sealing washer design, disconnect the transmission oil cooler (TOC) front upper pipe fitting from the radiator, discard the sealing washer, then cap the pipe fitting and plug the TOC fitting to prevent contamination.



7. If equipped with the flared fitting design , disconnect the TOC front lower pipe fitting from the radiator, allow any excess fluid to drain, then cap the pipe fitting and plug the TOC fitting to prevent contamination.



8. If equipped with the sealing washer design, disconnect the TOC front lower pipe fitting from the radiator, discard the sealing washer, allow any excess fluid to drain, then cap the pipe fitting and plug the TOC fitting to prevent contamination.
9. Drain the engine cooling system. Refer to Cooling System Draining and Filling in Engine Cooling.
10. Lower the vehicle; leave the vehicle on the hoist.
11. Recover the A/C system refrigerant.
12. Remove the air cleaner assembly. Refer to Air Cleaner Assembly Replacement in Engine Controls.
13. Remove the upper and lower radiator support. Refer to Radiator Support Replacement in Engine Cooling.
14. Disconnect the evaporator tube - front from the condenser. Refer to Evaporator Tube Replacement (Front) in HVAC Systems with A/C - Manual, or Evaporator Tube Replacement (Front) in HVAC Systems with A/C - Automatic.
15. Disconnect the compressor hose from the condenser. Refer to Compressor Hose Assembly Replacement in HVAC Systems with A/C - Manual, or Compressor Hose Assembly Replacement in HVAC Systems with A/C - Automatic.



16. Using the J 38185 , release and reposition the coolant surge tank upper hose clamp away from the radiator inlet.
17. Separate the surge tank upper hose from the radiator inlet.



18. Using the J 38185 , release and reposition the radiator inlet hose clamp away from the radiator inlet.
19. Separate the radiator inlet hose from the radiator inlet.



20. Using the J 38185 , release and reposition the radiator outlet hose clamp away from the radiator outlet.
21. Separate the radiator outlet hose from the radiator outlet.



22. Carefully pivot the A/C condenser with the radiator forward and tie off to support the assembly.



23. Remove the steering column intermediate shaft lower coupling shield.
24. Match-mark the intermediate shaft lower coupling to the power steering (P/S) gear to ensure correct orientation upon installation.
25. Remove the intermediate shaft lower coupling bolt.
26. Disconnect the intermediate shaft lower coupling from the P/S gear.

Slide the intermediate shaft lower coupling off of the P/S gear steering shaft.




27. Remove the P/S cooler retaining bolts.



28. Remove the brake pressure modulator valve bracket. Refer to Brake Pressure Modulator Valve Bracket Replacement in Antilock Brake System.
29. Remove the P/S gear mounting bolts and nuts.
30. Release the P/S gear and cooler from the front suspension crossmember, then slave the gear and cooler forward.
31. Remove the A/C compressor bracket. Refer to Compressor Mounting Bracket Replacement in HVAC Systems with A/C - Manual, or Compressor Mounting Bracket Replacement in HVAC Systems with A/C - Automatic.
32. Remove the generator from the accessory mounting bracket. Refer to Generator Replacement in Engine Electrical.
33. Install and support the engine with the J 41803 and the J 28467-B .
34. Remove the RH engine mount (with bracket). Refer to Engine Mount Replacement in Engine Mechanical.



35. Remove the TOC front pipe front clip.
36. Raise the vehicle.



37. Remove the TOC front pipe front retaining clamp bolt and retaining clamp.



38. Remove the TOC front pipe rear retaining clamp bolt and retaining clamp.
39. Disconnect the TOC front pipe fittings from the junction fittings at the engine flywheel housing, then cap the pipe fittings and plug the junction fittings to prevent contamination.
40. Lower the vehicle; leave the vehicle slightly above the ground.
41. Finesse the TOC front pipes out of the vehicle (through the top).

Tools Required

1. Install the transmission oil cooler (TOC) front pipes to the vehicle (through the top of the vehicle).

Finesse the pipes into position.

2. Raise the vehicle.
3. Remove the caps from the rear of the TOC front pipes and remove the plugs from the junction fittings at the engine flywheel housing.

Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

4. ALIGN and HAND-START, then tighten ONLY by hand to seat the TOC front upper and lower pipe fittings to the junction fittings at the engine flywheel housing.

Tighten
Tighten the transmission oil cooler front upper and lower pipe fittings to the junction at the engine flywheel housing to 27 N·m (20 lb ft).

5. Install the TOC front pipe rear retaining clamp and bolt.

Tighten
Tighten the transmission oil cooler front pipe rear retaining clamp bolt to 2.2 N·m (19 lb in).




6. Install the TOC front pipe front retaining clamp and bolt.

Tighten
Tighten the transmission oil cooler front pipe front retaining clamp bolt to 12 N·m (106 lb in).




7. Lower the vehicle; leave the vehicle slightly above the ground.
8. Install the TOC front pipe front clip.



9. Install the RH engine mount (with bracket). Refer to Engine Mount Replacement in Engine Mechanical.
10. Remove the J 41803 and the J 28467-B .
11. Install the generator to the accessory mounting bracket. Refer to Generator Replacement in Engine Electrical.
12. Install the A/C compressor bracket. Refer to Compressor Mounting Bracket Replacement in HVAC Systems with A/C - Manual, or Compressor Mounting Bracket Replacement in HVAC Systems with A/C - Automatic.
13. Position the power steering (P/S) gear and cooler to the front suspension crossmember.
14. Install the brake pressure modulator valve bracket. Refer to Brake Pressure Modulator Valve Bracket Replacement in Antilock Brake System.
15. Install the P/S gear mounting bolts and nuts.

Tighten
Tighten the power steering gear mounting nuts to 100 N·m (74 lb ft).




16. Install the P/S cooler retaining bolts.

Tighten
Tighten the power steering cooler retaining bolts to 11 N·m (97 lb in).




17. Connect the intermediate shaft lower coupling to the P/S gear; be sure that the intermediate shaft and the P/S gear steering shaft are orientated as marked prior to disconnecting them.

Slide the intermediate shaft lower coupling onto the P/S gear steering shaft.

18. Install the intermediate shaft lower coupling bolt.

Tighten
Tighten the steering column intermediate shaft lower coupling bolt to 34 N·m (25 lb ft).

19. Install the intermediate shaft lower coupling shield.



20. Remove the tie-off retainer and carefully pivot the A/C condenser and the radiator back into position.



21. Install the radiator outlet hose to the radiator outlet.
22. Using the J 38185 , position the radiator outlet hose clamp onto the radiator outlet.



23. Install the radiator inlet hose to the radiator inlet.
24. Using the J 38185 , position the radiator inlet hose clamp onto the radiator inlet.



25. Install the surge tank upper hose to the radiator inlet.
26. Using the J 38185 , position the coolant surge tank upper hose clamp onto the radiator inlet.
27. Connect the compressor hose to the condenser. Refer to Compressor Hose Assembly Replacement in HVAC Systems with A/C - Manual, or Compressor Hose Assembly Replacement in HVAC Systems with A/C - Automatic.
28. Connect the evaporator tube - front to the condenser. Refer to Evaporator Tube Replacement (Front) in HVAC Systems with A/C - Manual, or Evaporator Tube Replacement (Front) in HVAC Systems with A/C - Automatic.
29. Install the upper and lower radiator support. Refer to Radiator Support Replacement in Engine Cooling.
30. Install the air cleaner assembly. Refer to Air Cleaner Assembly Replacement in Engine Controls.



31. If equipped with the flared fitting design, remove the caps from the front of the TOC front upper and lower pipes and remove the plugs from the TOC.



32. If equipped with the sealing washer design, remove the caps from the front of the TOC front upper and lower pipes, install new sealing washers, and remove the plugs from the TOC.
33. Flush the TOC and TOC pipes. Refer to Transmission Fluid Cooler Flushing .
34. ALIGN and HAND-START, then tighten ONLY by hand to seat the TOC front lower pipe fitting to the radiator, if equipped with the flared fitting design.

Tighten
Tighten the transmission oil cooler front lower pipe fitting to the radiator to 40 N·m (30 lb ft).

35. ALIGN and HAND-START, then tighten ONLY by hand to seat the TOC front lower pipe fitting to the radiator, if equipped with the sealing washer design.

Tighten
Tighten the transmission oil cooler front upper pipe fitting to the radiator to 16 N·m within 4 N·m (12 lb ft, within 3 lb ft).




36. ALIGN and HAND-START, then tighten ONLY by hand to seat the TOC front upper pipe fitting to the radiator, if equipped with the flared fitting design.

Tighten
Tighten the transmission oil cooler front upper pipe fitting to the radiator to 40 N·m (30 lb ft).




37. ALIGN and HAND-START, then tighten ONLY by hand to seat the TOC front upper pipe fitting to the radiator, if equipped with the sealing washer design.

Tighten
Tighten the transmission oil cooler front upper pipe fitting to the radiator to 16 N·m within 4 N·m (12 lb ft, within 3 lb ft).

38. Lower the vehicle.
39. Connect the negative battery cable.

Tighten
Tighten the negative battery cable bolt to 15 N·m (11 lb ft).

40. Program the transmitters. Refer to Transmitter Programming/Synchronization in Keyless Entry.
41. Refill the engine cooling system. Refer to Cooling System Draining and Filling in Engine Cooling.
42. Evacuate and charge the A/C refrigerant system.
43. Check the transmission fluid level. Refer to Transmission Fluid Check .

Oil Cooler Hose/Pipe Replacement Rear

1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
2. Remove the intermediate exhaust pipe. Refer to Intermediate Pipe Replacement in Engine Exhaust.
3. Remove the RH muffler assembly. Refer to Muffler Replacement in Engine Exhaust.
4. Remove the driveline tunnel closeout panel. Refer to Floor Panel Tunnel Panel Reinforcement Replacement in Propeller Shaft.
5. Disconnect the transmission oil cooler (TOC) rear upper and lower pipe fittings from the junction fittings at the engine flywheel housing, then cap the pipes and plug the junction fittings to prevent contamination.



6. Disconnect the TOC rear upper and lower pipe fittings from the transmission fittings, then cap the pipes and plug the transmission fittings to prevent contamination.



7. Remove the TOC rear pipe rear clip.



8. Remove the TOC rear pipe middle clip.
9. Remove the TOC rear pipe front and rear clamp bolts and clamps.
10. Remove the TOC rear pipes from the vehicle.

1. Install the transmission oil cooler (TOC) rear pipes into position.

Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

2. Install the TOC rear pipe front and rear retaining clamps and bolts.

Tighten
Tighten the transmission oil cooler rear pipe front and rear retaining clamp bolts to 12 N·m (106 lb in).

3. Install the TOC rear pipe middle clip.



4. Install the TOC rear pipe rear clip.



5. Remove the caps from the rear of the TOC rear pipes and remove the plugs from the transmission fittings.
6. ALIGN and HAND-START, then tighten ONLY by hand to seat the TOC rear upper and lower pipe fittings to the transmission fittings.

Tighten
Tighten the transmission oil cooler rear upper and lower pipe fittings to the transmission fittings to 35 N·m (26 lb ft).




7. ALIGN and HAND-START, then tighten ONLY by hand to seat the TOC rear upper and lower pipe fittings to the junction fittings at the engine flywheel housing.

Tighten
Tighten the transmission oil cooler rear upper and lower pipe fittings to the junction fittings at the engine flywheel housing to 27 N·m (20 lb ft).

8. Install the driveline tunnel closeout panel. Refer to Floor Panel Tunnel Panel Reinforcement Replacement in Propeller Shaft.
9. Install the RH muffler assembly. Refer to Muffler Replacement in Engine Exhaust.
10. Install the intermediate exhaust pipe. Refer to Intermediate Pipe Replacement in Engine Exhaust.
11. Flush the TOC and TOC pipes. Refer to Transmission Fluid Cooler Flushing .
12. Check the transmission fluid level. Refer to Transmission Fluid Check .
13. Lower the vehicle.