I almost hate to bring this up. I've searched around and found some good info, but nothing clearly specific for the '96.

First, hereare the specific ofmy truck: 1996 Ram 4x4, 5.9L, auto trans.

Second, my problem. The trans cooling line are leaking at the connection between the rubber hose and the metal line. These of course are located in the engine bay near the radiator. As can be seen, I have the cooler built into the radiator.

I would like to 1) fix the leaking hose, and 2) install a Hayden heavy dutyaux cooler in front of the radiator/condenser. So here are the pics of my specific set up.








I've seen the "Hayden 396" fitting kit mentioned, however the Hayden website says no fittings are needed for a pre-99 truck. The service manuals I've seen don't look the same as my set-up either, it looks more like a post-99 set up.
So, some questions.Is there an adapter that will thread a barbed hose fitting on to the supply line where it connectsto the rubber hose (it looks like they should come apart w/ wrenches)?? And an adapter for the top (return) of the radiator, again with a barbed rubber hose fitting?? Is this the Hayden 396 kit?

The next issues to address are the connections at the bottom of the radiator, and to the metal line returning to the tranny. Would rubber hose and a worm hose clamp hold? Is there some specific "Swage" type fitting to attached to these metal line then allow rubber tranny hose to be secured?? I does not look as tho there is anyway to disconnected the rubber hose from the metal line on the return side, heading back to the tranny. Any thoughts on that (pipe cutter [dremel], and flare tool aside)?? I understand the need for the "quick disconnect tool", so I'll get one of those.

I know it's alot to ask for a newb, but any help would be appreciated. I may be new to the board, but I spend entire too much time on other (none Dodge related) forums. I look forward to gaining all the info, and providing what I know to this one.
Thanks y'all!!
-Jim

 

I didn't have the rubber lines leaking on mine, but I did install a B&M supercooler. I like the design a ton better for a truck, and would check it out if I were you. It's much stronger than a standard tube pass/ aluminum fin cooler. Most kits come with a variety of different adapters, and yes, if you just take the top cooler line out of the rad, you can put the aftermarket cooler inline. I had to take the factory adapter out of the radiator too, a step I wasn't expecting, but it all went back together without a problem. It comes with enough rubber hose to make it work and some worm gear type clamps. The cooler lines runs relatively high pressure, so you have to keep an eye on them to make sure they don't leak.

As far as the leaking lines, take both lines to a good shop that can either send out the lines to get redone, or go straight to the source. I don't exactly know where you are, but there's a dozen or so here in denver that can do it. The other option is to cut right before the rubber line, flare it, and get an AN adapter and run steel braided hose straight to the factory/aftermarket cooler combo. It would be worth looking at for a life long fix, plus it would look awesome!

 

Ok...This is a long explanation, and I'll be hanged if I can't find the pics of my installation. But here goes.
First, I'll assume you have the cooler and about 3 feet of 3/8 cooler line. Don;t use the wimpy 5/16 stuff. By a fuel line disconnect tool for the funky fittings taht slide over the metal lines. Hose clamps work fine, double them if your worried.
Remove the check valve by taking unscrewing it from the metal line.BTW...thats the(input) pressure line from the tranny.Go to your local NAPA store and get a hose nipple with the matching inverted flare threads for the tranny line. Then take the check valve and THROW IT OUT!
Use the disconnect tool and remove all the lines, leaving nice bare tube. Now you can run your lines. Mount the cooler to the front of the A/C coil.
Run your lines. I ran mine through the aux cooler first, then into the radiator. Then back into the tranny. That means from the check valve, to the cooler, radiator and back out. You can run cooler hose to the current steel line at the top of the radiator to the return line to the transmission.you can cut it shorter and use acrush sleeveadapter to mount a hose nipple.
I can probably shoot some pics if needed...

 

pics would be nice as i have the same problem

 

I'll have to shoot them tomorrow...too dark. But I'll take several.

 

is the check valve the small threaded cylinder on the pressure line where the tubing joins to the hose ?

 

Yup

 

Thanks for the replies guys!!
DD56, any pics would be very useful!

The only connection I don't understand how to get apart (aside from a dremel)is where the rubber hose is crimped on to the metal return line tube. It doesn't appear to have that funky disconnect fitting like the other 2 ends closer to the rad.

So far, y'alls soultion sounds do-able. Just got to find the right fittings now.

 

Lets see if I can post these here...
This how I elimnated the check valve, and yes, I ground off the outer coupler on the return line...and used a hose clamp



[IMG]local://upfiles/21672/7E4699191C2849C0A8F403F155FDF4F8.jpg[/IMG]

 

Ignore the tranny guage sender...use a hose clamp.

[IMG]local://upfiles/21672/8C62C5EEDC7D4EB39B19526F91A26070.jpg[/IMG]