tsherv

Hi,

I have a 2004 Freestar with the 3.9 engine. I pull a small enclosed trailer with it, and occasionally pull a 10' popup camper. The van has 125k miles on it. We just lost the torque convertor last month (thankfully there was a recall on it). So, I have a new torque convertor and fresh tranny fluid.

This summer I'm taking a longer trip with the camper (300 miles each way), and want to add a transmission cooler. I'm wondering how hard of a job this is as a DIY project? Looking at pictures, it looks like you just bypass the lines where they run into the radiator? Anyone have perspective on how difficult it is to add one to a Freestar?

Also, being I have brand new tranny fluid in it, I really don't want to have to replace it. If I do a tranny cooler, do I have to drain the tranny?

Thanks,

Troy

Bert

You don't have to drain the transmission. Here's some advice on the cooler install. Ford Freestar and Tran cooler [Archive] - Jayco Owner Forums

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Bert

tsherv

Thanks for the link. I'm confused though...the Jayco site that discusses installing a transmission cooler gives instructions on how to install one on a Freestar. The instructions say you need to drill holes in your transmission oil pan, install fittings, and run lines to your new cooler. This doesn't seem right to me. I thought an auxillary cooler was installed using rerouted lines by your radiator? I certainly don't want to be drilling holes in my transmission oil pan. Anyone have any insight into this?

Thanks.

Bert

THat site isn't the one I intended to post. The original lines can be used as in this post with pictures attached. Towing with a 03 Windstar(trans cooler) - Ford Forums Online - Ford Discussion & Enthusiast Forum

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Bert

tsherv

UPDATE - Last night I installed a Hayden Ultra Cool 404 in my 2004 Freestar. I have to say it was much more of a pain than I anticipated. My biggest issue was lack of room for mounting the cooler (in front of the AC condenser). The lack of space was very frustrating. It's hard to your hands in the tight spaces.

One other issue I had, I cut my transmission oil return line from the radiator (metal line) to tie in my cooler. I borrowed a double flare tool from Advance Auto. It was a brand new tool, but it would work. It kept slipping off the line. I thought the line was 3/8", but I'm starting to think maybe it's metric? Anyone have any ideas? Right now it's not flared, so I put 3 hose clamps on it. How dangerous is it to not flare it?

Thanks.

Bert

There isn't a lot of pressure in those lines so I think it'll be alright for now. Check with Autozone for a free loaner tool.

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Bert