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Revised Essential Tool J-35944-200-A Adapter For 9.525mm (0.375 in.) Automatic Transmission Oil Cooler Lines

Subject:Revised Essential Tool J 35944-200-A Adapter For 9.525 mm (0.375 in) Automatic Transmission Oil Cooler Lines

Models:2005-2006 GM Cars and Light Duty Trucks
with Automatic Transmission and 9.525 mm (0.375 in) Transmission Oil Cooler Lines


This bulletin is being revised to add 2006 model year vehicles. Please discard Corporate Bulletin Number 05-07-30-009 (Section 07 -- Transmission/Transaxle).

A new longer pilot 9.525 mm (0.375 in) automatic transmission oil cooler line went into production on some 2005 model year vehicles.

The new cooler line will not fit into the existing J 35944-200 adapter that is used with J 45096 Transmission Oil Cooler Flush and Flow Test tool. Refer to Corporate Bulletin Number 02-07-30-052C or newer -- Automatic Transmission Oil Cooler Flush and Flow Test Essential Tool J 45096 TransFlow (SI Document ID #1547813).

In the 2006 model year, all applications using the 9.525 mm (3/8 in) transmission oil cooler line will have the new, longer pilot cooler line.


Object Number: 1641363 Size: SH

First Design Cooler Line with Shorter Pilot


Object Number: 1641364 Size: SH

Second Design Cooler Line with Longer Pilot

A new adapter J 35944-200-A with a deeper opening can be purchased from Kent-Moore/SPX Customer Service but will not be shipped essential.

J 35944-200 Adapter Modification

J 35944-200 can be modified to allow it to work on both the first design and second design cooler lines.

  1. Remove the O-ring seal from the J 35944-200.

    2. Notice: 

       • Use care not to drill deeper than 9.525 mm (0.375 in). Drilling deeper than 9.525 mm (0.375 in) may damage the fitting.
       • Use care to drill straight through the fitting. Drilling the fitting on an angle may damage the fitting.

    Tip
    A piece of rubber hose will work well for the drill bit depth stop. Place the rubber hose over the drill bit that allows an additional 9.525 mm (0.375 in) drill depth. This will keep the drill bit from drilling deeper than desired.

  2. Mark a 9.525 mm (0.375 in) drill bit to a depth that will drill the opening 9.525 mm (3/8 in) deeper.

    3. Object Number: 1641366 Size: SH
  3. Drill fitting J 35944-200 9.525 mm (0.375 in) deeper using a 9.525 mm (0.375 in) drill bit.
  4. Clean out any metal shavings from the fitting using shop air and a rag.
  5. Re-install the O-ring seal. A new O-ring (Kent Moore/SPX P/N 11439) is available from Kent-Moore/SPX Customer Service if needed.