2001 Windstar Transmission Line Removal

[macavada]

New to the forum, did a few searches and couldn't find exactly what I was looking for. I've got a 2001 3.8L Windstar.

I took my van in for a transmission fluid exchange, and the little lip on the transmission end of the lower transmission line ended up with a crack in it. So, it now leaks when installed back into the retaining clip. The guy at the shop explained to me how the clip works (squeezing it, correct?) to release the transmission line. My question is, how do you get the line off the radiator side? Is it basically the same principle? Do you need any special tools? It looks different from the end that connects to the transmission. I haven't been able to get in there with a light yet.

Thanks for any responses.

[12Ounce]

Why would you want to remove the line? I would think you would disconnect the line .... as before and then replace the plastic insert.

A trip to Ford parts counter should get you the info and part(s) you need. Ask for a print-out of the exploded parts view of external transmissin parts.

[macavada]

The plastic insert wasn't broken. The metal tube that goes into the clip on the transmission side of the line has a hairline crack along the ring that's formed into the metal tube (make sense?). When they removed the line to do the exchange, the metal tube at the end cracked. I don't see what they could have done to crack this tube. It seems to me like it could have been defective for it to crack the way it did.

I went to the parts house at Ford, and they weren't very helpful in sharing information on how to get the transmission line off at the radiator/cooler side. I tried to ask about how to disconnect the line and they just said I don't know and you need a special tool, you can't do it yourself. They said it could cost an hour of shop time to replace the part, and I don't want to get into that.

I ordered a replacement transmission fluid line - the lower one - and looked at a diagram, but it wasn't very helpful.

I've done plenty of repairs in my time, and this one doesn't seem to be too difficult, although there isn't a lot of room behind that radiator to fool with getting the transmission line disconnected.

So, anybody know how it comes off and if I need a special tool? Is there a trick to it?

Thanks again.

[12Ounce]

OK, now I understand your problem better.

I took a look in the shop manual ... the removal must pretty straight-forward ... "remove retainer and remove tube" ... later, "install tube and reinstall retainer" ... no special tools called out that I see.

[rodeo02]

Originally Posted by macavada

..I went to the parts house at Ford, and they weren't very helpful in sharing information on how to get the transmission line off at the radiator/cooler side. I tried to ask about how to disconnect the line and they just said I don't know and you need a special tool, you can't do it yourself..

That's about the exact response you'd get from any of my local dealer parts counters. No help at all aside from selling you parts.

Joel

[MARZBX157]

I have a 2000 Windstar which is simular to yours and I have the CD repair manual. In reading it I see no call for any speacial tools, just remove the retaining clip then remove the tube. Only thing I see is that it's a tight space.

[macavada]

Thanks for the replys. I'll giver her a try this weekend.

[MARZBX157]

Let us know how it goes for you. Also a good idea is to install an aux oil cooler since the windstar tranny is prone to failures. I just purchased one from B&M Racing (70268) and will be installing it at 60K miles. Just a thought.

[phil-l]

I installed a B&M transmission cooler in my 2000 LX 3.8 when I began towing a popup camper. A very useful upgrade.

I made it a point to run the lines so that it's now very easy to do quick drain-and-refill tranny fluid changes.

Pics of this project (and some other Windstar towing-related stuff):

http://rides.webshots.com/album/549196858rbUAlb

[MARZBX157]

Phil, did you need any other parts other than the one the kit came with?
I see that you cut the tube which runs from the lower line. What did you use to cut it. Did you have to remove the tube to do this? Thanks

[Johnny Mullet]

Just cut the line with a tubing cutter and flare it so the hoses stay clamped on.

[phil-l]

marzbx157 -

I used a tubing cutter (commonly available at Home Depot in the plumbing department) and was careful to clean all metal particles from the outside and inside of the tube after cutting. The tubing is made from soft metal; it cuts easily. I flared it slightly (just using, as I recall, a pair of closed needle nose pliers), but there's very little pressure in the cooling lines. A standard hose clamp is plenty to hold the hose on the tube end.

I did not remove the tube from the van to cut it. It was kind of a tough fit to turn the tubing cutter, but far easier than removing the tube. Where I cut the tubing is (basically) under the radiator. It's a long, straight section of tubing at this point, so I was able to manuver the tube enough to work on it.

I found that the amount of hose included in the B&M kit wasn't enough; I had several feet of spare hose laying around, so it wasn't a big deal.

I also wanted something more secure than the sheet metal screws included in the kit. I replaced them with bolt/nut/lock washer combinations.

For the other side of the connection, I also needed a way to couple the new hose to the flexible hose I cut. There are spiffy barbed coupler fittings out there: I must admit that I simply cut a short piece of tubing left over from the metal tubing I removed to make the first connection, with a hose clamp on each side. Again, I cleaned everything and flared it slightly. It works fine.