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Three Long Years of Testing

 

 

The Need

 

            Like so many other Dodge truck owners, I purchased my truck to tow.  While the Cummins is one tuff power plant, the automatic transmission that came in the truck had its share of problems.  In gas-fueled vehicles they fair much better, but the huge torque the Cummins produces really takes it toll on them.  Dodge addressed some of the problems along the way, which helped.  But still there is a huge difference in the percentage of transmission failures of the Diesel powered trucks vs. the gasoline-powered trucks.  While the reasons behind the failures vary, there is one common thread that stands out among them all, HEAT.  Heat is the number one reason for transmission failure, so if we address that area, we can greatly reduce our chances of having a transmission failure.  This was the reason I built the Super Cooler line of automatic transmission coolers. 

 

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Figure 1 This is our 12V Cummins and one of the trailers used to test the Super Cooler.

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Figure 2 This is a Hallmark "EDGE" trailer.  It is 36' long has a Kodiak front end and weighs about 17,000lbs.

            Anyone that has a HD Dodge truck can benefit from the Super Cooler.  But, if you tow or haul heavy loads, you NEED a Super Cooler to make your transmission live.  The extra load put on the automatic transmission during towing can be three to four times the load the transmission see’s when not towing.  This extra load is often converted to extra heat, which we already know is the number one reason for transmission failure.  While towing the transmission goes through many heat cycles.  When we start out, the transmission heats quickly to it’s “Normal” range, 160-175°F.  As you drive through city traffic, every start sends the fluid through a heat cycle.  This heat is produced from the torque Converter, as the fluid is set into motion, from the clutches and bands as they operate to switch gears, and from the torque convert as it locks up.  This scenario is repeated with every stop and start.  If the cycles are repeated to rapidly and or to often, like in heavy city traffic, or stop and go highway snares, the transmission quickly begins to loose it ability to maintain a safe fluid temperature.  It is not uncommon to see transmission fluid temperatures of 180-210°F in normal traffic situations.  And 210-240°F temperatures in moderate to heavy traffic conditions.  In extreme situations readings of 260°F and higher are not hard to record.  How do I know this?  I spent the last three (3) years testing the Super Cooler in both normal and towing conditions, with both heavy and light towing.  That is exactly how I know.  Since the transmission builds heat with every action it makes, and these actions can be widely varied, we need a transmission cooler that is just as widely varied, the Super Cooler.

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Figure 3  The Dodge RE 48 Transmission

 

The Super Cooler has the ability to change its cooling capacity as the transmission builds heat.  In most normal conditions, towing or not, the Super Cooler has the capacity to keep the transmission fluid in check. With an Average temperature range of 140-155°F., the Super Cooler lowers normal readings by some 25-40°F.  And in heavy traffic conditions while towing, the Super Cooler averages a transmission fluid temperature of 165-180°F, some 45-70°F cooler with a non-cooler equipped truck.  That is the difference between your transmission surviving the trip or frying itself.

 

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Figure 4  B&M's HY-TEK Cooler W/Fan Assembly

 

Transmissions need heat to operate and function as intended. There are actually heat exchangers built into the system that help the transmission fluid come up to temperature quickly.  This allows the transmission to operate efficiently in both cold and hot climates.  This also makes selecting the right size and type of auxiliary cooler an important decision.  You do not want to over-cool the fluid, rather assist it in keeping the fluid in check and provide added protection when needed.  This is one reason we choose the B&M HY-Tek cooler as the cooler for our kit.  It is extremely well made and is pressure tested to 200 psi..It has large ½” fittings, fin and plate design, and incorporates an electric fan which is automatically controlled by its own thermostat.  This feature allows the cooler to work in many different scenarios, without the worry of over-cooling, all in a completely automatic mode.  Our testing has shown this combination works extremely well in all types of traffic conditions and in all truck configurations.

Reliability, a small word that means so much.  No system is worth having if it is not reliable, no matter what the cost.  One of the very reasons many site as the reason for purchasing a Cummins/Dodge truck is reliability.  With this in mind, we set about to build the Super Cooler.  First off, we found the best cooler to use for the job, the B&M Hy-Tek cooler.  As stated earlier, it is one tough piece.  Next came the mount, I wanted the mount to be strong, reliable, ease to access and used to help protect the cooler.  Our mounts are made of  steel tubing, with a steel screen that protects the cooler from debris.  They are welded by professional fabricators that care about the products they build, and powder-coated for lasting great looks.  All hardware we use is Stainless Steel and the position of the mounts allows for ample cooling, without detracting from any other function on the truck. 

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Figure 5  A row of SC 100 Mounts wait for their coolers.

  

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Figure 6  SC 100 mounts complete with HY-TEK coolers

 

 

In the kits you will find only the best hoses and fittings.  We use Stainless Steel Braided High Performance hoses and fittings.  The same hoses and fittings used by race teams in NHRA, ASA, and NASCAR.  Again, we went with the best because we wanted reliability.  They are all pre-terminated, tested and ready to install.

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Figure 7  A group of Hoses right after assembly and testing, awaiting shipment.

 

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Figure 8  A 90°, Straight, and 45° AN 8 Performance fitting.

 

 

           

            Electrical: The kit comes with its own custom made harness, simply plug one end into the cooler connection and connect the other to the vehicles battery.  A remote indicator light is furnished if you would like to know when the cooling fan turns on.  And we also include a lead for hooking up a temperature gauge if you choose.

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Figure 9  A shot of the electrical harness.

 

And finally we arrive at the complete kit.  I wanted this to be a complete and all-inclusive kit, meaning everything needed to install the kit was there.  So we provided everything needed to do the job right.  All that is needed on your part is a few common hand tools and a drill.  Average install time will be from 1-2 hours, depending on your level of experience and knowledge.  If you can change your own oil, you can install this kit, it’s that simple.

 

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Figure 10  SC100 Kit

 

 

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Figure 11  SC110 Kit

 

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