terna Transmission i ooer it

External Transmission Oil Cooler Kit

Suitable for:

Please read through all of the instructions carefully before proceeding. If any of the information does not appear correct or the diagrams don’t match your vehicle,

please contact Wholesale Automatic Transmissions on +61 3 9762 8004.

Toyota Prado 150 Series 5 and 6 Speed

Automatic TransmissionWITH THE FOLLOWING ENGINES:

1GD-FTV 2.8L Diesel, 1KD-FTV 3.0L Diesel, 1GR-FE 4.0L Petrol, 1KD-FTV 3.0L Diesel

External Transmission Oil Cooler Kit to Suit:Toyota Prado 150 Series 5 and 6 Speed AutomaticW.A.T.

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1 x M6x20mm SEMS Bolt For Mounting

Bracket

Safety FirstHot engines and hot transmissions can cause serious injury.

Before removing the hoses and parts from the vehicle, allow sufficient time for engine and auto to cool.

Parts ListCross Flow Oil Cooler

Pre-Mounted to Bracket Plus Retainer Bracket

4 x 8-16mm Stainless Steel Cooler Line Screw

Clamps

2.5m x 10mm High Temp Cooler Line Hose

with Conduit

5 x 300mm Cable Ties

Expected Installation Time: 2 Hours


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Summary of Installation - For Experienced Fitters• Ensure you have enough transmission oil to top up your transmission.• Remove the plastic cover above the radiator by removing the plastic clips.• Remove the lower bash plates / covers (if fitted) below the front of the vehicle.• Disconnect the “hot line” rubber hose that brings hot transmission fluid into the top right

of the radiator. Follow the hose back to where it connects to a metal pipe running from the transmission then disconnect the hose from this metal pipe.

• Remove protective rubber socks from your new transmission cooler fittings.• Cut the provided cooler line in half. Fit one half of the line to each side of the cooler - FIT

IT DRY - DO NOT use lubricant. • Clamp the cooler lines to the cooler unit fittings using the provided screw clamps.• Slide the cooler bracket and hoses down in front of the radiator. • Unbolt the following from the vehicle: 2 x horns, the lower bolt that holds the center

radiator support• Mount the cooler and remount the 2 x horns by attaching them to the original horn

mounting bolt holes. The horns must be mounted facing the reverse direction (toward the back of the vehicle). Do not fully tighten the bolts at this point.

• Locate the bolt hole at the bottom left of the cooler. Bolt the cooler to your vehicle using this hole. Do not fully tighten the bolts at this point.

• Locate the last remaining bolt hole on the bottom of the cooler bracket. Insert the bolt into the cooler bracket and tighten the bolt into the bolt hole.

• Tighten all cooler bracket bolts.• Cut a hole in the foam below the radiator to allow the cooler hoses to pass through into

the engine bay. Route the hoses through this hole.• The two hoses running from the bottom of the cooler can now be connected. One should

be routed to the top right of the radiator where the original OEM transmission “hot line” was attached. The other should be routed to the metal pipe coming from the transmission where the other end of the OEM hot line was attached.

• Trim hoses to required lengths and attach using the supplied stainless steel hose clamps.• Use supplied cable ties to secure hoses as required.• Road test vehicle then re-inspect cooler and fittings for leaks. Tighten if necessary.


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Detailed Installation Instructions

Before commencing work, please ensure that you have sufficient transmission fluid to top up

at the end of the job.

1. Ensure the car is fully switched off. It is recommended that the vehicle is cold prior to installation.

2. Open bonnet.

3. Remove the plastic cover above of the radiator. This can be completed by removing the clips as pictured below.


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4. Remove the front grill.

5. Remove the lower bash plates / covers (if fitted) below the front of the vehicle.


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6. Locate the hose that returns the transmission fluid back to the transmission.This will be located at the top drivers side of the radiator. Disconnect this hose from the radiator. See below picture.

7. Follow the hose under the vehicle to where it connects to a metal pipe running to the transmission and disconnect the hose from this fitting. See below pictures indicating which pipe to remove and the fully removed hose.


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8. Remove cooler rubber protectors as shown.

9. Cut the supplied cooler line in half. Undo the hose clamps enough to looselyfit over the supplied cooler line.

10. Slide the first half of the cooler line onto either fitting on the cooler. THISMUST BE DONE DRY. DO NOT USE LUBRICANTS.


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11. Tighten the hose clamp.

12. Repeat the previous steps to attach the second half of the cooler line to the other side of the cooler.


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13. Unbolt the following from the vehicle and retain all bolts: 1/ Both of the horns 2/ The lower bolt that holds the lower radiator support (as indicated in the photograph below).


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14. The cooler can now be mounted to the radiator support. This will involve attaching the cooler and horns into the mounting holes that originally held the horns. However, the horns must be mounted facing the reverse direction. This will be detailed in the following steps. The below picture shows the final result.

15. Take the two bolts that mounted the horns and fit them to the two holes on the top of the cooler bracket.

16. Take the two horns and slide one onto each bolt. The horns must be mounted in the reverse direction to the original - ie. so they are facing toward the rear of the vehicle.

17. Bolt the cooler bracket and horns to the vehicle as indicated by the previous picture. Leave the bolts loose for now.


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18. Locate the top bolt hole of the two located at the bottom left of the cooler (as you face the radiator) as indicated below.

19. Using this top hole pass the OEM radiator support bolt removed earlier through the cooler bracket, then through central radiator support, then tighten it into the vehicle frame where it was originally located. Refer to below picture for the location of the OEM radiator support bolt.


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20. To attach the final cooler bracket bolt, locate the last remaining bolt hole on the bottom of the cooler bracket. See picture below. Insert the supplied 1 x M6x20mm SEMS bolt through the cooler bracket into the bolt hole in the vehicle frame and tighten the bolt.

21. Fully tighten all bolts fixing the cooler to the vehicle.

22. The installed cooler and bracket should look similar to the below picture:


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23. Cut out a section of the foam below the radiator as indicated in the below pictures. The cooler hoses must be routed through the hole created.


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24. Route the two hoses running from the bottom of the cooler through the hole cut into the foam earlier.

25. Take one of the cooler hoses (it does not matter which as the cooler is not directional). Route it to the radiator fitting where the original OEM transmission “hot line” was removed earlier. Cut it to length. Attach it to the fitting using the supplied stainless steel hose clamp. See picture:


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26. Take the second hose and route it to the steel fitting running from the transmission where you removed the OEM transmission hose earlier. Cut the hose to length. Attach it to the OEM fitting using the supplied stainless steel hose clamp.


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27. Use supplied cable ties to secure hoses as required.

28. Start the car. While the car is running locate and remove the 24mm fill plug on the driver side of the transmission.


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29. Locate and remove the 5mm allen key head “Check Plug” located in the sump of the transmission. DO NOT remove the 14mm bolt located nearby as this is the transmission drain plug.

30. Carefully top up the transmission fluid through the fill plug until the fluid is fully flowing out of the check plug hole.

31. Carefully watch the fluid flowing out of the check plug hole and once the flow flickers, quickly put the check plug back in and tighten. Return the 24mm fill plug and tighten.

32. Clean all underneath areas of transmission fluid

33. Road test then visually check for leaks and retighten any fittings as required.


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34. With the engine still running, recheck fluid level by removing the Check Plug and checking if oil dribbles out as per previous instructions above. If no oil is present please top up the oil level as directed earlier in this instruction. PLEASE NOTE: THE TRANSMISSION FLUID MAY BE QUITE HOT. PLEASE TAKE CARE WHEN UNDOING CHECK PLUG BOLT.

35. Check again for any transmission fluid on the vehicle and clean off.

36. If bash plates were removed reinstall them in reverse order.

37. Road test vehicle then re-inspect cooler and fittings for leaks. Tighten if necessary.

This completes the installation of the Wholesale Automatic Transmission External Cooler Kit.

Please remember ALL automatic transmission have a service interval of 2 years or 40,000km to improve the longevity of the transmission.

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