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Transmission Fluid Cooler Leaks at Radiator

WARNING: This page is about a different car, the 2005 Ford Pickup, 2005 Ford F550 Super Duty, 2005 Ford F450 Super Duty, and 2005 Ford Cab & Chassis. However, it is still accessible from the selected car via links, so may be relevant.

Transmission fluid may leak between the radiator transmission fluid cooler and the transmission fluid cooler fitting (not the cooler tube into the fitting), which may result in a residue of transmission fluid on the radiator tank around the fluid cooler fitting. Insufficient thread sealer on the transmission fluid cooler fitting may cause this.

Fig 1: Identifying Transmission Fluid Cooler Fitting (1 Of 2)
G03923168Courtesy of FORD MOTOR CO.
  1. Clean the area around the transmission fluid cooler fittings.
  2. Verify that transmission fluid is leaking between the transmission fluid cooler and the transmission fluid cooler fitting (not the transmission fluid cooler tube fitting into the transmission fluid cooler fitting).
    Fig 2: Identifying Transmission Fluid Cooler Fitting (2 Of 2)
    G03923169Courtesy of FORD MOTOR CO.
  3. Remove the radiator from the vehicle and place it on a flat surface with the transmission fluid cooler fittings facing upward. For additional information, refer to ENGINE COOLING .
    4. CAUTION: Oil-based solvents and cleaners should not be used when cleaning the radiator. Oil-based solvents and cleaners can damage the radiator end tank seals and cause leaks.
    Fig 3: Removing Transmission Fluid Cooler Fittings
    G03923170Courtesy of FORD MOTOR CO.
  4. Clean the area around the transmission fluid cooler fittings so that contaminants do not enter the transmission fluid cooler when the transmission fluid cooler fittings are removed.
    5. NOTE: Remove only one transmission fluid cooler fitting at a time, otherwise the cooler may drop into the radiator.
  5. Remove the upper transmission fluid cooler fitting.
  6. Once the fitting is removed from the transmission fluid cooler, verify that there is a gasket between the transmission fluid cooler and the inside of the radiator tank.
    • If there is no gasket, install a new radiator.
    • If there is a gasket, continue with this procedure.
      Fig 4: Identifying Transmission Fluid Cooler Gasket
      G03923172Courtesy of FORD MOTOR CO.
  7. Inspect the transmission fluid cooler fitting threads for damage.
    • If the threads are damaged, install a new radiator.
    • If the threads show no sign of damage, continue with this procedure.
      • Fig 5: Identifying Transmission Fluid Cooler Threads
      G03923171Courtesy of FORD MOTOR CO.
    8. CAUTION: Thread sealant or tape should never be used on the threads of the transmission fluid cooler fittings. The use of such materials will create a leak path.
    Fig 6: Installing New O-Ring On Transmission Fluid Cooler Fitting
    G03923173Courtesy of FORD MOTOR CO.
  8. Install a new O-ring on the transmission fluid cooler fitting.
  9. Making sure that the gasket between the transmission fluid cooler and the inside of the radiator tank is still in place, install the upper transmission fluid cooler fitting.
    • Tighten to 60 Nm (44 lb-ft).
      Fig 7: Installing Upper Transmission Fluid Cooler Fitting
      G03923174Courtesy of FORD MOTOR CO.
    10. NOTE: Remove only one transmission fluid cooler fitting at a time, otherwise the cooler may drop into the radiator.
  10. Remove the lower transmission fluid cooler fitting.
  11. Once the fitting is removed from the transmission fluid cooler, verify that there is a gasket between the transmission fluid cooler and the inside of the radiator tank.
    • If there is no gasket, install a new radiator.
    • If there is a gasket, continue with this procedure.
      • Fig 8: Identifying Transmission Fluid Cooler Gasket
      G03923172Courtesy of FORD MOTOR CO.
  12. Inspect the transmission fluid cooler fitting threads for damage.
    • If the threads are damaged, install a new radiator.
    • If the threads show no sign of damage, continue with this procedure.
      Fig 9: Identifying Transmission Fluid Cooler Threads
      G03923171Courtesy of FORD MOTOR CO.
    13. CAUTION: Thread sealant or tape should never be used on the threads of the transmission fluid cooler fittings. The use of such materials will create a leak path.
    Fig 10: Installing New O-Ring On Transmission Fluid Cooler Fitting
    G03923177Courtesy of FORD MOTOR CO.
  13. Install a new O-ring on the transmission fluid cooler fitting.
  14. Making sure that the gasket between the transmission fluid cooler and the inside of the radiator tank is still in place, install the lower transmission fluid cooler fittings.
    • Tighten to 60 Nm (44 lb-ft).
  15. Make sure that no radiator coolant has entered the transmission fluid cooler. Install the radiator in the vehicle. For additional information, refer to ENGINE COOLING .
  16. Verify that both the transmission and the engine cooling system are at the correct fluid levels.
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