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Old 09-08-2013, 10:57 AM   #1
Furious_8
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Default Ford Falcon Automatic Tranmission Cooling Units

Hi,

Please use this thread as a reference for all the standard cooling units fitted by ford to cool the Automatic Transmission


EA, EB & ED Falcons with 4 Speed Automatic
One of the best designed systems as these ran very cool in standard form. The cooling unit was an Exchanger inside the Drivers side radiator tank. It used steel pipes from the transmission with screw in threads.

Aftermarket Cooler Kits
Not really needed unless towing and a PWR 200x280x19 cooler in series with the radiator was fine.


EF & EF Falcons with 4 Speed Automatic
In my opinion the hottest running transmission temp in all falcons heat always killed this transmission. The cooling unit was an Exchanger inside the Drivers side radiator tank. It used steel pipes from the transmission with screw in threads.

Aftermarket Cooler Kits
A must for any vehicle which did high kms and towed a PWR 200x280x19 cooler in series with the radiator is a minimum the larger 255x280x19 in series or complete by-pass was very popular option.

Quote:
"I had taxis getting 350,000kms + out of there transmissions with external coolers fitted and transmission fluid changers every 50,000kms limp mode always killed cab boxes"



AU Falcons with 4 Speed Automatic

The more open front of the AU allowed for good cooling these ran very cool in standard form. The cooling unit was an Exchanger inside the Drivers side radiator tank. It used steel pipes from the transmission with screw in threads.

Aftermarket Cooler Kits
For some reason customers liked to tow with the AU and the PWR 200x280x19 cooler in series with the radiator was an option but the larger 255x280x19 in series was very popular. With the series 2 and 3 AU's seem to start seeing split radiator cores so by-passing was also a good idea it wasn't common but the series 3 was worse.

Quote:
"Furious Performance recommended kit TCK-F25510."



BA & Early BF Falcons with 4 Speed Automatic

So what happened here? I cant remember how many water effected transmission rebuilds i did for the local ford dealer. The cooling unit was an Exchanger inside the Drivers side radiator tank. It used steel pipes from the transmission with screw in threads. There was no noticeable difference between the BA & AU but the BA suffered big time. Aftermarket radiators with different cores where a must.

Aftermarket Cooler Kits
The popular option of fitting a PWR 255x280x19 in complete by-pass of the radiator was a must.


Quote:
"Furious Performance recommended kit TCK-F25510."


The Introduction of the Heat Exchanger (6cyl Engines Only)

After the Radiator issues a new design cooler was used known as the Heat Exchanger which is a small unit fitted to the engine under the inlet manifold. It uses Plastic lines from the transmission with a unieqe Quick Release fitting. In the early stages the exchanger seem to last coming off the back of the BA radiator problems. However the water issue raised its head again but in a different way, rather than a complete failure it started with seeping water and was able to be pickup during a Transmission Service. If left to long it would completely go and fill the transmission with water. There are some cases where it just fills the coolant system with transmission fluid and the transmission can be flushed wont need a rebuild.


Late BF 6cyl Falcons with 4 Speed Automatic

The first to see the Heat Exchanger which is a small unit fitted to the engine under the inlet manifold. It uses Plastic lines from the transmission with a unieqe Quick Release fitting.

Aftermarket Cooler Kits for 6cyl Falcons with 4 Speed Automatic
Customers who Towed or Owned a Taxi fitted a PWR 255x280x19 in complete by-pass of the exchanger as the 4 speed is known to run hot in those conditions and adapting the external cooler so it was in series is difficult. With the water problems showing up again i believe its a safe bet to fit a cooler to completely by pass the heat exchanger.


Quote:
"Furious Performance recommended kit TCK-F25513."



BF 6cyl Falcons with 6 Speed Automatic

The first to see the Heat Exchanger which is a small unit fitted to the engine under the inlet manifold. It uses Plastic lines from the transmission with a unieqe Quick Release fitting.

Aftermarket Cooler Kits for 6cyl Falcons with 6 Speed Automatic
With the water problems showing up again i believe its a safe bet to fit a cooler to completely by pass the heat exchanger and possibly save yourself the cost of a new transmission ($7000 average cost of 6spd rebuild).

Quote:
"Furious Performance recommended kit TCK-F25513 other kits available please see other thread"



BF 8cyl Falcons with 6 Speed Automatic
Because the V8 engine has exhaust either side the transmission cooling unit is an Exchanger inside the Drivers side radiator tank. It uses steel pipes from the transmission to the front of the engine. Then there are plastic lines from there to the radiator which use a unieqe Quick Release fitting.

Aftermarket Cooler Kits for 8cyl Falcons with 6 Speed Automatic
Water problems still show with this system and its the coolest running factory setup for the 6 speed also. However i believe its a safe bet to fit a cooler to completely by pass the heat exchanger and possibly save yourself the cost of a new transmission ($7000 average cost of 6spd rebuild).

Quote:
"Our TCK-F25513 kit has very similar cooling and flow results to the BF V8 Falcons Factory cooling system."



FG 6cyl Falcons with 4 Speed Automatic
These still use a Heat Exchanger which is a small unit fitted to the engine under the inlet manifold. It uses Plastic lines from the transmission with a unieqe Quick Release fittings.

Aftermarket Cooler Kits for 6cyl Falcons with 4 Speed Automatic
Customers who Tow can fit a PWR 255x280x19 in complete by-pass of the exchanger as the 4 speed is known to run hot in those conditions and adapting the external cooler so it was in series is difficult. With the water problems still a big ???? i believe its a safe bet to fit a cooler to completely by pass the heat exchanger.



FG 6cyl Falcons with 5 Speed Automatic
These still use a Heat Exchanger which is a small unit fitted to the engine under the inlet manifold. It uses Steel pipes from the transmission with a unieqe metal quick release fittings.

Aftermarket Cooler Kits for 6cyl Falcons with 5 Speed Automatic
The 5 speeds use a different design cooler than the 4 & 6 speeds its not know to fail as often but these are still a very expensive transmission to rebuild ($5000 average cost for a 5spd rebuild).



FG 6cyl Falcons with 6 Speed Automatic

These still use a Heat Exchanger which is a small unit fitted to the engine under the inlet manifold. It uses Plastic lines from the transmission with unieqe Quick Release fittings.

Aftermarket Cooler Kits for 6cyl Falcons with 6 Speed Automatic
With the water problems showing up again i believe its a safe bet to fit a cooler to completely by pass the heat exchanger and possibly save yourself the cost of a new transmission ($7000 average cost for a 6spd rebuild).



FG 8cyl Falcons with 6 Speed Automatic

Because the V8 engine has exhaust either side the transmission cooling unit is an Exchanger inside the Drivers side radiator tank. It uses steel pipes from the transmission all the way up to the radiator which use unieqe male Quick Release fittings.

Aftermarket Cooler Kits for 8cyl Falcons with 6 Speed Automatic
The FG V8's seem to be the worst for blown radiator cores the design of using a male pipe and a female radiator connection seem to be an issue. i believe its a safe bet to fit a cooler to completely by pass the heat exchanger and possibly save yourself the cost of a new transmission ($7000 average cost of 6spd rebuild).

Quote:
Furious Performance Cooler kit History....
I developed the first Furious Performance Heat exchanger bypass kit in early 2009. It was fitted to a 2009 SY Territory which was based in Young NSW. The customer a family friend had me fit it with only 9,000kms as he did alot of towing and a friend of his had already replaced a transmission in his BF due to water. Still to this day that vehicles transmission has been fault less as to the many other thousands of customers as well.
Cheers
Rhys Bloomfield
Proprietor
Furious Performance
www.furiousperformance.com.au

Last edited by Furious_8; 09-08-2013 at 11:22 AM.
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Old 10-08-2013, 07:22 PM   #2
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Default Re: Ford Falcon Automatic Tranmission Cooling Units

Will you be doing any forum specials for the 6 speed auto coolers.

What are the differences between a cooler for a falcon 6sp and a territory 6sp
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Old 11-08-2013, 06:01 PM   #3
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Default Re: Ford Falcon Automatic Tranmission Cooling Units

Currently not right now on the kits which connect into the factory lines as the RRP should be $330 but if you want a custom kit which uses fittings at the transmission i will soon have some options listed.

Cheers
Rhys

Quote:
Originally Posted by RHR View Post
Will you be doing any forum specials for the 6 speed auto coolers.

What are the differences between a cooler for a falcon 6sp and a territory 6sp
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Old 11-08-2013, 06:11 PM   #4
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Default Re: Ford Falcon Automatic Tranmission Cooling Units

I fitted the AU kit to my daughters car. Threw in a new rad at the same time.

I bypassed the rad all together.

These kits are a must on AU and BA. There has been lots of gearboxes destroyed due to the in rad cooler tank failing.

Its a easy DIY mod.
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Old 11-08-2013, 07:57 PM   #5
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Default Re: Ford Falcon Automatic Tranmission Cooling Units

So are there any differences between the terry cooler and the falcon cooler.


Edited
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Last edited by RHR; 11-08-2013 at 08:19 PM.
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Old 11-08-2013, 08:24 PM   #6
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Default Re: Ford Falcon Automatic Tranmission Cooling Units

The eBay listings are really out of date as they have links on multiple websites this forum being one of them haven't really touched them.

The Territory & BF Falcon kit are the same but i remove one of the brackets for the falcon and also have different instructions. I get alot of calls form BF customers wondering what the left over bracket is when i leave it in as its not needed so i split the listings.

The FG (TCK-F255FG) kit has new brackets and also different instructions. The 5 speed FG (TCK-F255XT) kit has new fittings so there is no cutting of the lines.

Quote:
Originally Posted by RHR View Post
So are there any differences between the terry cooler and the falcon cooler.
Your fleabay listing on the terry 6 speed auto one is confusing as it states its larger (cooler) but when you look at the dimensions provided its smaller than the one listed for the falcon 6 speed auto
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Old 11-08-2013, 08:49 PM   #7
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Default Re: Ford Falcon Automatic Tranmission Cooling Units

Talking to the old man today, when he was pre-delivering falcons in the early 70's it wasnt unusual to find a milkshake on a brand new car. 40 years and they still havent got it right.
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Old 11-08-2013, 08:50 PM   #8
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Default Re: Ford Falcon Automatic Tranmission Cooling Units

Terry listing

http://www.ebay.com.au/itm/Ford-Terr...3d72a62&_uhb=1

Falcon listing fg

http://www.ebay.com.au/itm/Ford-FG-F...e0742b0&_uhb=1

Falcon listing bf ( note same images used in listing)

http://www.ebay.com.au/itm/Ford-BF-F...7dd391e&_uhb=1

So why the price difference

bit confusing
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Last edited by RHR; 11-08-2013 at 09:03 PM.
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Old 14-08-2013, 06:14 PM   #9
Furious_8
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Default Re: Ford Falcon Automatic Tranmission Cooling Units

The original Kit was for a SY Territory

TCK-T25513
www.furiousperformance.com.au/retail_catalogue/TCK-T25513_item.html

or

www.ebay.com.au/itm/140456176226?


I then Adapted it to a BF Falcon

TCK-F25513
www.furiousperformance.com.au/retail_catalogue/TCK-F25513_item.html

or

www.ebay.com.au/itm/140523682078?

Then i created a net kit to suit the FG with new brackets.

TCK-F255FG
www.furiousperformance.com.au/retail_catalogue/TCK-F255FG_item.html

or

www.ebay.com.au/itm/1408****5792?

This kit then needed a new version to suit the 5 speed box as it needed new Female Adapters rather than male like all the rest

TCK-F255XT
www.furiousperformance.com.au/retail_catalogue/TCK-F255XT_item.html

or

www.ebay.com.au/itm/150682499298?

Then after many requests i designed and developed the XR6 Turbo kit whic is a direct bolt on to the BF but if you let me know its for an FG i can ad an extra bracket to help fit the cooler.

TCK-FURXR6
www.furiousperformance.com.au/retail_catalogue/TCK-FURXR6_item.html

or

www.ebay.com.au/itm/150961837006


I also have braided hose options for the BF & FG 6 speeds.

I just like to make sure i have them all the models covered.
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Old 14-08-2013, 06:28 PM   #10
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Default

Plenty of ppl with fg xr6 turbos running this kit tho, the one without the fan http://www.furiousperformance.com.au...55FG_item.html
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Old 15-08-2013, 09:01 AM   #11
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Default Re: Ford Falcon Automatic Tranmission Cooling Units

I'm currently running this system and its been great, no difference in the performance of the transmission and piece of mind no milkshakes. Easy to install however the brackets needed to be slightly modified to suit the FG but again very easy.

Some pics of it installed behind the drivers side Fog light on my G6E turbo.





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Old 15-08-2013, 07:20 PM   #12
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Default Re: Ford Falcon Automatic Tranmission Cooling Units

Thanks for the feedback on the kit and the images.

Cheers
Rhys
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Old 15-07-2014, 02:26 AM   #13
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Default Re: Ford Falcon Automatic Tranmission Cooling Units

Hey Furious 8

What do you have for an EL XR8 BTR
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Old 15-07-2014, 01:10 PM   #14
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Default Re: Ford Falcon Automatic Tranmission Cooling Units

Quote:
Originally Posted by helby View Post
Hey Furious 8

What do you have for an EL XR8 BTR

Hi,

Our TCK-F25510 kit will have all the hose & fittings to complete the job but the instructions and brackets are for a AU falcon. You can shorten the brackets and use a P-Clamp to secure the bottom of the bracket to the power steer cooler.

The only other problem is on the EL you normally need to remove the front bumper bar also.

Cheers
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Old 27-07-2014, 01:40 PM   #15
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Default Re: Ford Falcon Automatic Tranmission Cooling Units



Would there be any chance that you could put up this instruction manual via PDF or similar?
I would just like to have a read if possible.

I'm just looking at FG falcon.
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Old 09-08-2014, 10:38 AM   #16
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Default Re: Ford Falcon Automatic Tranmission Cooling Units

I want to fit a bypass kit on my fg gtp 335. Which kit is best suited?
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Old 24-08-2014, 05:47 PM   #17
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Default Re: Ford Falcon Automatic Tranmission Cooling Units

Quote:
Originally Posted by EASPRINT View Post
I want to fit a bypass kit on my fg gtp 335. Which kit is best suited?
Sorry for the long delay im not sure if these cool the trans via the radiator or a exchanger bolted to the engine some where.

The XR8 uses the radiator on the drivers side.
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Old 26-08-2014, 09:19 PM   #18
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Default Re: Ford Falcon Automatic Tranmission Cooling Units

Quote:
Originally Posted by Furious_8 View Post
Sorry for the long delay im not sure if these cool the trans via the radiator or a exchanger bolted to the engine some where.

The XR8 uses the radiator on the drivers side.
Via the radiator
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Old 14-09-2014, 04:36 PM   #19
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Default Re: Ford Falcon Automatic Tranmission Cooling Units

well sorry for the thread dig but have just purchased one for the BA Mk2.

Can not wait to fit it now.
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Old 18-09-2014, 04:54 PM   #20
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Default Re: Ford Falcon Automatic Tranmission Cooling Units

There seem to be 3 different ones for the ZF FGs. What's the difference between them, except for the fact that the most expensive one has a fan on the cooler?

Would the $330 TCK-F255FG bolt up to a G6E Turbo or is the intercooler in the way?
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Old 25-04-2019, 08:46 PM   #21
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Default Re: Ford Falcon Automatic Tranmission Cooling Units

G'day everyone,

I drive an '07 RTV, 190 barra with a four speed trans.

I've been reading all about the transmission cooler issues our Fords have and decided I should have a closer look at my own.

Turns out it has a trans cooler fitted in front of the radiator (which I gather is a good thing), routed through the heat exchanger below the manifold (which I gather is NOT such a good thing.

I understand that a regular setup now is to have a trans cooler which bypasses the heat exchanger altogether, therefore removing the risk of engine coolant contamination in the trans fluid.

My question is: If I want to achieve this bypass, can I just remove the engine coolant hoses from the heat exchanger, join them together and just leave the transmission fluid running through the heat exchanger?

My thinking is: The engine coolant issue would then be completely removed, so, is there any point going to the trouble of disconnecting the transmission fluid pipes and joining them together? Is there any harm having the trans fluid running through the exchanger?

Just trying to save a little time/effort.

I'd appreciate your thoughts
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Old 03-08-2019, 04:55 PM   #22
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Default Re: Ford Falcon Automatic Tranmission Cooling Units

Quote:
Originally Posted by djohnn955i View Post
I drive an '07 RTV, 190 barra with a four speed trans.
I have the same car

I also have the Air/Oil cooler mounted in front of the radiator. I understand that this is a component of the factory option tow-pack

Quote:
My question is: If I want to achieve this bypass, can I just remove the engine coolant hoses from the heat exchanger, join them together and just leave the transmission fluid running through the heat exchanger?
I visited PWR Head office/factory as its a different config to standard BF2 so they could have a look. They confirmed they don't have a kit to fit, but the guy suggested doing what you have described.

Except that he added to remove the Heat exchanger entirely, which means looping both the oil and the water pipes back on themselves.

He did note, that he doesnt know how effective the factory install air/oil cooler will be on its own, and that their model would be much better.



Quote:
I'd appreciate your thoughts
what did you end up doing?
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Old 03-08-2019, 05:54 PM   #23
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Default Re: Ford Falcon Automatic Tranmission Cooling Units

I just did as I suggested. IE: loop coolant hoses together and left the trans fluid running thru heat exchanger.
I guess it would be a neater solution if I were to loop the trans fluid hoses but didn't have the fittings handy and couldn't see any harm leaving as is.
So far so good and no dramas 😁.
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Old 04-08-2019, 04:14 PM   #24
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Default Re: Ford Falcon Automatic Tranmission Cooling Units

Quote:
Originally Posted by theBlake View Post
I have the same car

I also have the Air/Oil cooler mounted in front of the radiator. I understand that this is a component of the factory option tow-pack


I visited PWR Head office/factory as its a different config to standard BF2 so they could have a look. They confirmed they don't have a kit to fit, but the guy suggested doing what you have described.

Except that he added to remove the Heat exchanger entirely, which means looping both the oil and the water pipes back on themselves.

He did note, that he doesnt know how effective the factory install air/oil cooler will be on its own, and that their model would be much better.




what did you end up doing?
What is the size of the factory cooler. May not be large enough.

I would say it need to be equivelent to min 150mm x 280mm. If you tow it needs to be 200mm x 280mm. 0r 255mm x 280mm
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Old 04-08-2019, 04:41 PM   #25
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Default Re: Ford Falcon Automatic Tranmission Cooling Units

Quote:
Originally Posted by arronm View Post
What is the size of the factory cooler. May not be large enough.
Havent measured it, have a Smartbar in the way, but sure as eggs this its this one mentioned elsewhere 540x80x19mm, its Factory installed with the tow kit. Which measures up slightly better than the 150x280 you mentioned. (i dont tow)


Quote:
Originally Posted by djohnn955i
I just did as I suggested. IE: loop coolant hoses together and left the trans fluid running thru heat exchanger.
I guess it would be a neater solution if I were to loop the trans fluid hoses but didn't have the fittings handy and couldn't see any harm leaving as is.
So far so good and no dramas 😁.
A couple of things that I just thought of,
- there will still be coolant in the heat exchanger.
- the heat exchanger has a job to do to bring the transmission up to operating temperature.

whether these things matter, I Dunno.
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Old 09-08-2019, 10:14 PM   #26
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Default Re: Ford Falcon Automatic Tranmission Cooling Units

Bypass the heat exchanger and just use the front mount cooler , being a 4 speed it will be fine...

Take the coolant hoses off the heat exchanger and join them..
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