05 42RLE Transmission Cooler Lines

[billlaaayyy]

Been watching an issue with a slow drip under my 2005 SE (4.0 automatic) which has been getting a bit worse over the last few weeks. Never a puddle and keep checking fluid levels and been OK, but think it's time to replace my cooling lines. Seems to be lots of leaking coming from my cooling lines, and am going to use some UV dye to try and pinpoint it exactly.

If needing to replace the lines entirely, I am unsure which to go with!

Seems I need DORMAN 624094 replacements - which at auto parts stores are coming up $300+. RockAuto is showing them around $180, or SSTubes has them for about $100. Is this a get what you pay for situation or a case of a new solution less expensive than 20 year old parts? Ive seen some Youtubers being able to replace without dropping exhaust, but not 100% sure thats an option so might also do the RMS at the same time and just open it all up (maybe). Ideally just don't want to be down too long this summer

Are the alternative lines a good pathway? Any extra parts to have on hand, or look out for? THANKS!!

(New England based, not off-road really - so not looking to add an additional cooler, just fix what is plaguing me today!)

 

[TexasTJ2004]

How do you know that it is the lines and the not a leak from the connector itself? Did anybody work on it lately and did not fasten the bolts?
These lines are metal, so they don’t leak easily unless you have severe corrosion

 

[billlaaayyy]

no work done recently regarding transmission or lines. I added a 2 inch lift a few weeks ago, maybe jiggled things up. I will check on tightening down the bolts first, and see if perhaps that is all it is

 

[TexasTJ2004]

On the top photo you definitely see that the leak is coming from the connection to transmission itself.
Also, can you clean the lines with the brake cleaner or something, and repost the photos?

 

[billlaaayyy]

Cleaned up a bit, and caps pulled back. Upper / lower. Perhaps it is the connector. Do the o-rings inside go bad?

 

[billlaaayyy]

seems the culprit is further up the line — a bit....crusty.... UV dye lighting up in/around the bracket

 

[Rcroane]

Seems like a set of these is in your future.....

https://www.rockauto.com/en/moreinfo.php?pk=13832589&cc=1430906&pt=10343&jsn=418

 

[billlaaayyy]

Seems like a set of these is in your future.....

https://www.rockauto.com/en/moreinfo.php?pk=13832589&cc=1430906&pt=10343&jsn=418

Yupppp, I've had them in my cart for a few days anticipating it. Was curious though about a) the other options (sstubes with the option around $100 - https://www.sstubes.com/products/wt...l-complete-transmission-cooler-line-kit-steel ) - is that a reasonable option, or stay away? and is the only way to snake the new ones back in is with the exhaust detached? Don't mind if that's the only option, but like the motto of the less you touch the less you can break .

 

[Rcroane]

Yupppp, I've had them in my cart for a few days anticipating it. Was curious though about a) the other options (sstubes with the option around $100 - https://www.sstubes.com/products/wt...l-complete-transmission-cooler-line-kit-steel ) - is that a reasonable option, or stay away? and is the only way to snake the new ones back in is with the exhaust detached? Don't mind if that's the only option, but like the motto of the less you touch the less you can break .

I don't have any experience with SS Tubes....hopefully, others will chime in.

I had my mechanic install mine. He took an unorthodox approach to installing them so he didn't have to mess with the exhaust. He cut the lines into two pieces and then joined them back together with compression fittings. They've been leak free for about two years now. Not sure I'd recommend you try that at home! He's a bit of a maverick, but I always trust his work.

 

[billlaaayyy]

doesnt sound *that* unorthodox, I think I saw a few fixes/repairs/solutions with that method on the tube as well. Not preferred to cut brand new, BUT, might be better. But i also need to do the rear main, so might be the time to do it all at once and just suck it up

 

[voodooridr]

I ordered a set from Mopar when my '06 blew a cooler line, figured the OEM line went 140k miles

 

[billlaaayyy]

ended up ordering the replacements from Lines2go - stainless, and shipped in 3 days. Got the old ones out, and have zero clue on getting the new ones back in. Directions leave a lot to be desired (https://www.linestogo.com/jeep-wrangler-transmission-line-set-2005-4-0l-tcl-111-ss1a/) - such as which direction to start from? Feed from front to back, or transmission forward? Info says 2 of the 02 sensors need removal, and of course the lower one isnt budging and the upper I cant reach. I disconnected the leads, in case that would at least help with getting around things, but were unable to even get the lines into a place where the 02 sensors are causing an obstruction. Tried youtube to see about how to get them back in, but no luck :-(. Was hoping this would be a fairly easy one, but kinda stuck now!

 

[Rcroane]

ended up ordering the replacements from Lines2go - stainless, and shipped in 3 days. Got the old ones out, and have zero clue on getting the new ones back in. Directions leave a lot to be desired (https://www.linestogo.com/jeep-wrangler-transmission-line-set-2005-4-0l-tcl-111-ss1a/) - such as which direction to start from? Feed from front to back, or transmission forward? Info says 2 of the 02 sensors need removal, and of course the lower one isnt budging and the upper I cant reach. I disconnected the leads, in case that would at least help with getting around things, but were unable to even get the lines into a place where the 02 sensors are causing an obstruction. Tried youtube to see about how to get them back in, but no luck :-(. Was hoping this would be a fairly easy one, but kinda stuck now!

Which direction did the old ones come out? I think I would try that route...e.g. if they came out front to rear, try routing the new ones in front to rear. Is there another auto Jeep near you that you could look at to remind you of the routing path?

 

[billlaaayyy]

Which direction did the old ones come out? I think I would try that route...e.g. if they came out front to rear, try routing the new ones in front to rear. Is there another auto Jeep near you that you could look at to remind you of the routing path?

they came out with tube cutters. That, and the point of failure broke with just a little wiggling/bending.

 

[Rcroane]

they came out with tube cutters. That, and the point of failure broke with just a little wiggling/bending.

Ah...got it. Are you trying to get them in without dropping the exhaust? If it helps, I can snap a pic of where mine were cut and put back together for the install. If it were me, I'd walk away for a bit and see if anyone chimes in with install tips.

 

[Jamison C]

ended up ordering the replacements from Lines2go - stainless, and shipped in 3 days. Got the old ones out, and have zero clue on getting the new ones back in. Directions leave a lot to be desired (https://www.linestogo.com/jeep-wrangler-transmission-line-set-2005-4-0l-tcl-111-ss1a/) - such as which direction to start from? Feed from front to back, or transmission forward? Info says 2 of the 02 sensors need removal, and of course the lower one isnt budging and the upper I cant reach. I disconnected the leads, in case that would at least help with getting around things, but were unable to even get the lines into a place where the 02 sensors are causing an obstruction. Tried youtube to see about how to get them back in, but no luck :-(. Was hoping this would be a fairly easy one, but kinda stuck now!

I bought these same lines when I did my auto swap. Sturdy build and routed fine. Made in Canada I believe.

 

[billlaaayyy]

Ah...got it. Are you trying to get them in without dropping the exhaust? If it helps, I can snap a pic of where mine were cut and put back together for the install. If it were me, I'd walk away for a bit and see if anyone chimes in with install tips.

Yup — absolutely. called it quits for the night and will look at it again tomorrow. Was frustrated and knew it was time to pause.

And yes, I think my assumption was with the new ones, you didnt need to drop the exhaust. accessing those bolts look worse than getting 02's out.

tomorrow is another day

 

[billlaaayyy]

I bought these same lines when I did my auto swap. Sturdy build and routed fine. Made in Canada I believe.

did you drop exhaust, or get the 02 sensors out? curious!

and yup, they came down from Nova Scotia!

 

[Jamison C]

did you drop exhaust, or get the 02 sensors out? curious!

and yup, they came down from Nova Scotia!

I had my exhaust out. I don't see any way you could do it without moving the exhaust.

 

[billlaaayyy]

I had my exhaust out. I don't see any way you could do it without moving the exhaust.

Sadly I was kinda thinking that, just by the path of the lines. I have my rear main on my to-do list too.... Maybe I try and get the exhaust down and tackle that to. Bolt access on the exhaust is like zero too erghhh