10R80 Transmission Cooler Project

[TJC]

Tony, is the plenum something you are going to sell? Or perhaps a complete package?

I haven't given any thought to it. At this point it is premature to consider. I'll cross that bridge when I get to it.

I will certainly publish results and sources for the parts. I can tell you now it isn't inexpensive, but it is much less than a rebuilt/new transmission that may fail the same way.

I can also tell you that I have not removed the first part on my truck in this replacement process.

And I already know the heat exchanger is tucked away in very tight quarters. It is going to be a challenge to replace it. I may even have to remove the transmission crossover mount and lower the transmission to get to it. My first attempt will be through the driver side front fender well. If you change your own oil, you can see the heat exchanger to the right from that vantage point. But it is a tight fit... probably as bad as installing the UPR Catch Can lines. I did that work and it was no fun.

There is simply no room to see or move your hands in that tight space. It's another reason I want all those coolant hoses (that will become unnecessary if I am successful) removed.

Back to the transmission, IMO, Ford has not really addressed the issue. The solenoids (magnetic, they end up sticking - attracting ferrous residue from wear components) and other valve body parts used are inadequate, but the firmware and high heat level exacerbate the weakness. The lack of a dipstick or simple way to change the fluid is a big problem. The fluid needs to be changed far more often than Ford will ever admit.

I may very well end up having a rebuilt transmission before this is over, and if I do, I will go with a high quality aftermarket valve body and replacement parts. I will not be going to Ford to seek another faulty transmission.

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[TJC]

I've spent the last couple of weeks buying a cheap HF Metal Brake and transforming it into something useful for this project. Hopefully, it will allow me to make the fan plenum. Had to wait on parts and pieces to arrive to complete the project.

I started with the $50 30" Metal Brake (on sale at my local Harbor Freight). I didn't like the idea of using C clamps to hold the brake top plate in place. Constant repositioning and lack of definable repeatable quality bends drove me to find a solution. Researched the internet and found several folks who modified the brake to make it useful. I took some of their ideas and began to modify my brake.

Tested it today with good success. Still need to tweak a few adjustments, but I think its going to do what I want.

Here's what I started with... The top bar simply floats on the bed and must be clamped using C clamps (not included) for each bend... way too inaccurate and time consuming.

...and that shiny pieced of aluminum in the back left against the garage door is going to be my plenum. The top plate sits on the back section of the brake - held in place with C clamps.

And here is the finished product... Locking clamps on each side that raise and lower a 2" x 2" x 1/4" x 34" long piece of steel angle iron. The top metal brake plate is attached to the angle iron by stainless steel 1/4" x 20 bolts going through 3/8" aluminum spacers... I tapped into the top brake plate.

I've got adjustments for all 3 axis. Once tuned in it stays tuned in.

And I've got less than $100 in it. This should make quick work of the plenum.

The brake is mounted to a 2" x 10" x 48" board held in place on my 40 year old Workmate 300. This is it in the locked position, It makes perfect 90 degree bends up to 30". I plan to store it flat on the garage wall.

Shortly it will be time to transfer my pattern to the aluminum, cut the fan center hole, and then start bending metal into the fan plenum, and finally mounting it to the 40 row stacked cooler.

Once the cooler unit is completed, I'll fabricate the mounting plate, test fit, and mount the completed assembly to the truck. Then build the AN8 hoses and route them from the transmission to the cooler. I'll need to add another ~1 quart of transmission fluid as well.

I'll test for leaks before running the necessary wiring and configuring the digital fan controller.