We got ours installed yesterday, not a difficult job at all, but wanted to take our time and do it right.. Some things I did a little differently than the original poster:
We mounted ours in series with the radiator since the radiator has recently been replaced.
We mounted the cooler first, on the driver's side of the middle grill support and relocated the horn to the support. I was able to bend two of the brackets that came with the cooler to secure from the middle support on one side and from the A/C condenser mounting tabs on the other side. By mounting this way I was able to avoid using the zip ties to mount through the radiator and condenser, AND was able to provide a little more separation to improve air flow. The horn relocation looks a little goofy, but it's behind the grill, and I may replaced those stock beepers with honkers later on. I thought about splicing the horn lead and putting it beside the passenger side horn but I want to do as little "Frankenstien'ing" to this car as possible.
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I routed the hoses after mounting the cooler, through the hole for the A/C lines, but I routed the return line back to the transmission behind the hood latch framing and the supply line along the lower bumper framing. My concern is rocks or road debris damaging the lines, so I wanted to have these as hidden as possible.
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As for going through the hole, I tried a few different methods of protecting the hoses and none of them seemed to work really well without cramping the hoses and A/C lines in that space. So right now the hoses are just going through the hole without any kind of sleeving or protection. My thought on that is that while protecting the hoses would be ideal, I'd rather leave that space uncramped, and also since that piece is a part of the body, the hoses will move it, they should not be rubbing back and forth against that metal regularly. Adversely there are a couple of protective sleeves on the original transmission lines that could maybe be removed and used here. Open to thoughts or suggestion here, I'll probably revisit this area, I may try experimenting with some header wrap or something similar.
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I was able to do this job without spilling one drop of transmission oil. I got the new hoses routed first, and had the new hoses resting at the locations I was going to tie in to, at the return nipple located on the driver's side of the radiator, and the hard return line back to the transmission located (conveniently) above the front end cross member in a tiny little rat's nest of a space. I did the radiator side first by loosening the factory hose clamp, twisting the hose on the nipple to break it free, and slowly pulling the hose off the nipple and immediately pointing the hose upward. As soon as I had the old hose off, I put the new hose on.
At the other end I ended up having the cut factory hose off the hard line with a box cutter. Again I immediately pointed the hose end upward, and put the new hose onto the end of the hard line. Now holding the factory hose with both ends up I pulled the dipstick and back into the pan the oil went. It worked great, didn't lose any oil out of the system, and a nice clean install.
So we added about a half a quart of new Dexron-III when we were completely finished, it shifts smooth, but still registers low on the dipstick. By the way, I HATE THAT DIPSTICK!!! I don't want to overfill it, but I know I didn't lose any oil from the system and I couldn't imagine that little cooler using up a full quart of oil. I wanted to get some other's perspectives on that. We used the B&M 70264, I haven't seen any reference to the volume of this cooler, but I would have liked to have been able to only add the exact volume of the cooler plus a tiny bit extra for the volume of the additional hose.
Any thoughts or ideas on how much oil to add, or on the hose protection are welcome!!
Thanks again to the OP for the write-up it was more than helpful! And I'm happy to share details on our install with anyone else who may be looking to do this to theirs...
Happy 4Runner:
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Thaaaa Twins:
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