[Resolved] 05 Expy - Transmission cooler line leak

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Bommer

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Hello all,

I woke up to find a nice stain on the driveway under the front of my expy and isolated it to a pinhole leak in one of the transmission cooler lines right near the driver side frame where the 2 lines are held together in a plastic clip full of salt and debris.

I checked the dipstick and found it was bone dry. I topped up the fluid and started the engine to see the fluid spray in a barely visible stream from a very rusted line.

I am wondering if anyone knows if I could use a compression fitting and some steel brake/fuel line to replace the heavily rusted section.

My Expy is edging on 300,000kms, so a cheaper repair is the #1 option.
When I get around to replacing the rattling cam phasers and timing chain I'll worry about replacing the line.
 

Jimdar

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Several years ago I noticed my tranny lines were rusty and seeping. Brought it to my mechanic who cut off the rotten steel and replace the bad sections with high pressure hose with double clamps on each side. He assured me it was an acceptable alternative to replacing the entire line. So far it's holding up just fine.
 

1955moose

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I have a friend of mine with an early chevy el camino, that repaired his leaking transmission line with a length of hose and multiple clamps also. So far 2 months later it's holding. If you do this type of repair, keep in mind it's temporary, and you should replace the line with the proper metal one. Good luck.


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Bommer

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The good news:
So I cut the line and replaced the rotted section with hydraulic line rated for 600° and 800 psi. That should hold for a while.

The bad news:
The line from radiator to external cooler is now leaking right at the bottom connection to the radiator.
 

1955moose

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Never ends does it? Got to use all those tools for something. Remember it's better to mess up fixing your SUV twice yourself than paying some dill hole to do it once.


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Bommer

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Question for the experts... If I remove the lower quick connect fitting from the radiator itself, will coolant leak out?

Is the heat exchanger sealed to the radiator body, or is it secured by the fitting?

I was thinking of hitting Lowes and just building something I can screw in.
 
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Bommer

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Fixed. Went to the local wreckers and searched every Expedition and Ford pickup. Found 4 with the same fitting as mine, but with a finer thread. Found an F250 with a slightly different shape for the plastic retaining clip, but identical thread pitch and length.
Took that fitting and the foot of trans line connected to it. Paid $2.50.

Installed the fitting in the rad, the line into the fitting, and a steel 3/8 - 3/8 compression union. Did the same to the original broken line with 2 of the unions and a fresh piece of steel tube in between. No more leaks and no need for rubber line.

I managed to break my lower coolant hose clamp in the process though. :(

I replaced it with a regular worm gear clamp.

Now I pray I roll on over to 300,000km with no more fuss.
 

1955moose

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Prayers can come true, but doesn't hurt to check every thing every day or so for next few days just to be sure. Keep a bottle of coolant and some tranny fluid and funnel. That's what I'd do. And church on Sunday. Who knows you might have another Ford guy in your church or temple!


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Bommer

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So far I've been checking every hour. Not a sign of anything leaking. I have an oil change appointment at the dealership, my brother is one of the mechanics, so I'll have him look it over.
 

1955moose

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Good deal.


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