Transmission cooler hoses part number

[littlemike777]

Hello folks. I have searched for this and can’t find anything straightforward. I have ‘04 TJ bought about 2 years ago, still finding things the previous owner did, I.e., Geri rigging etc.
Driving today started smelling burning, smoking, didn’t smell like engine oil or radiator, stopped but couldn’t find anything. Then started getting transmission slipping and barely would go. No fluid on the dipstick. I had a quart of fluid with me, put it in and made it to O’Riellys and bought some more, added a quart and that got it to top end of the dipstick. Started driving trying to make it home, about 4 miles from there slipping really bad but I could not pull off the road, very little shoulder and deep ditches on both sides in the middle of nowhere. Kept going, engine rev, then trans would engage briefly for another 50 yards or so. Did this for about a mile until I could pull over and call for a tow.
Got under it when I got home and saw one of the hoses from the trans to the radiator was a plain rubber hose, not preformed and was very close to the main fan pulley , only about an inch clearance between the hose and the pulley. Apparently vibration caused it to rub a hole in the hose, pulled the fluid out and fan blew it everywhere. Likely transmission is shot but I’m praying not.
I’m trying to find the proper hoses that go from the radiator to the steel lines , I assume they are preformed or routed in such a way to avoid being that close to the pulley, but I can’t find part numbers or good diagrams. I will get another plain old hose tomorrow on it and fill the fluid just to test and see if the transmission is fried but I need to have the right hoses and correct routing so this doesn’t happen again.
Any help is greatly appreciated!!!

 

[Unique Username]

Sounds like she was running low on fluid for a bit to long.

I learned years ago that transmissions ain’t hard to deal with when it comes to internals. The tricky part is the electrical.
If you burned it up you have 2 options.
1) Used replacement
2) Rebuild

My crack head brother in-law had been doing it for most of his adult life and the more digging I did the more I found most transmission folks were on par.
Since I had rebuilt more then my share of ZF transmissions I figured why not give this a go. All that’s needed is some snap ring tools and large feeler gauges. You can pick this all up fairly cheap and replace the clutch packs and sun shell yourself if you want to save a few bucks. You will be under $1,000 for a full rebuild, rebuilt torque converter and a hand full of parts From Sonax.
This is a prime time to rebuild the transfer case as well, but that will be additional cost. If anything, at least do a drain and fill on that poor bastard.

If you want to get replacements hoses, pull the OEM lines, cut the clamps off very carefully not to damage the old lines. Once the rubber is removed, drive up to an auto parts store and they will take you in the back to look at hoses. Find oil line that fits good on that line. Usually 11/32 braided fits snug, but play around with the inventory and see what fits snug.
Since no one will stock good clamps, order some good hose clamps to hold on the new hose to the lines.

If you pick up a rebuilt, take the old one and learn on it as it may be needed.

Last note, keep and eye on that fluid and keep it cool.