Gearbox cooler

Types of Gearbox Cooler

The gearbox cooler is a device used in vehicles to maintain the gearbox temperature. It prevents the gearbox from overheating and increasing its efficiency. There are several types of gearbox coolers, such as:

• Oil cooler

  The oil cooler uses coolant oil to transfer heat away from the oil of the gearbox. It has two main types:

  • Tubular cooler

    The tubular cooler has a tube running through the center of the cooler. The tube holds the water or coolant, while the other tubes hold the coolant's oil. The tubes are parallel to each other and sit side by side. They are all connected at the end in the same direction like a train. When the oil is pumped into the tubes, it flows in the opposite direction of the water. As a result, the oil is cooled along the entire length.

  • Plate cooler

    The plate cooler has several plates stacked on top of each other. The plates create two channels, one for the oil and another for the water or coolant. The channels run parallel to each other but are opposite on the plate. The water or coolant moves in the opposite direction of the oil. As a result, the temperature between the oil and water is the same along the plate. This ensures the oil is cooled evenly along the plate.

• Air cooler

  The air cooler uses airflow to remove heat from the gearbox. It comes in two main types:

  • Transmission cooler

    The transmission cooler is mounted on the front grill of the vehicle, where there is a constant flow of air. It has tubes that heat exchange between the cooler's oil and the air flowing through the cooler. The tubes are connected in a zig-zag pattern, allowing the air to move between them. When the vehicle is in motion, the air flows through the cooler, transferring the heat from the oil and cooling it.

  • Fan cooler

    The fan cooler contains a fan that forces the air to flow through the cooler. The fan is connected to a switch that is turned on when the gearbox is overheated. The fan also has a thermostat that turns it on automatically when the temperature reaches a certain level. The fan and the thermostat are usually combined into one unit, which is cheaper and takes up less space. It is also portable, allowing it to be fitted onto existing transmission systems.

Specifications and Maintenance of Gearbox Coolers

Gearbox coolers are vital components in vehicles, especially those with automatic transmissions. They ensure the longevity and efficiency of the transmission system by regulating its temperature. Understanding the specifications of gearbox coolers can help retailers source the right products for their target market. Here are some common specifications:

• Size and dimensions

  Coolers are available in various sizes and dimensions to cater to different vehicles and their gearbox sizes. The cooler's dimensions affect its cooling efficiency and installation space requirements. A larger cooler has a bigger surface area, which offers a more excellent heat dissipation rate than a smaller one.

• Material

  This component is mainly constructed using aluminum or copper. Each material has its advantages. Aluminum is lightweight and corrosion-resistant, making it a popular choice. Copper has better thermal conductivity than aluminum, which enables faster heat transfer.

• Flow rate

  The flow rate is the amount of transmission fluid passing through the cooler within a given timeframe. It is measured in liters per minute. A higher flow rate improves the heat exchange efficiency, thus cooling the fluid more effectively. The flow rate is determined by the gearbox design and cooler's internal structure.

• Cooling capacity

  Gearbox coolers have different cooling capacities measured in watts or British thermal units (BTUs). The cooling capacity indicates the amount of heat the cooler can remove from the gearbox cooler per unit time. A higher cooling capacity means the cooler can handle more heat, making it suitable for high-performance vehicles subjected to high-stress driving conditions.

• Mounting type

  This refers to how the gearbox cooler is mounted on the vehicle. The cooler can be mounted on the radiator or directly on the fan. Those mounted on the radiator are more common and easy to install. Moreover, they have a larger space for heat exchange due to their proximity to the engine.

Maintaining a gearbox cooler is crucial to ensuring its efficiency in regulating gearbox temperature. Here are some maintenance tips:

• Regular Inspection: It is important to regularly inspect the gearbox cooler for any wear and tear, damage, or leaks. Also, check the transmission lines for any cracks or leaks and replace the damaged parts immediately.

• Clean the Gearbox Cooler: Over time, dust and debris can accumulate on the cooler, affecting its cooling performance. Gently clean the gearbox cooler to avoid damaging the fins. A soft brush or compressed air can remove the debris and dust.

• Monitor Transmission Fluid: The level and quality of transmission fluid is a key component in the performance of the gearbox cooler. Ensure the fluid level is at the manufacturer's recommended level. Also, change the fluid after a given mileage as instructed by the manufacturer.

• Monitor Temperature: Always keep an eye on the transmission temperature gauge. If the temperature rises above the normal range, there might be a problem with the gearbox cooler. Consult a professional mechanic to diagnose the issue and fix it accordingly.

How to Choose Gearbox Cooler

Business buyers looking for a gearbox cooler need to consider several factors to ensure they get the right unit for their needs. Here are some of them:

• Application

  Buyers should first consider the application in which the cooler will be used before purchasing a gearbox cooling system. For instance, a cooler used in an off-road application where the vehicle operates in extreme conditions and loads needs to have an enhanced cooling capacity compared to one used in a city driving application.

• Transmission type

  Another thing buyers need to consider is the transmission type. They need to ensure that the gearbox cooler is compatible with the transmission type, whether manual or automatic.

• Size and capacity

  Buyers need to choose a cooler that has the right size and cooling capacity for the gearbox they want to install it on. If the cooler is oversized, it will lead to overcooling, which can damage the gearbox. On the other hand, a smaller cooler will not be able to provide the adequate cooling that the gearbox requires.

• Environmental considerations

  Buyers need to consider the environmental conditions where the cooler will be installed. For instance, a cooler installed in a coastal area will need to have a corrosion-resistant feature compared to one installed inland.

• Mounting and space

  Buyers need to consider the available space for installing the gearbox and the mounting options available. They should choose a cooler that is easy to mount and install in the available space.

• Budget

  Lastly, buyers should purchase a gearbox cooler that is within their budget. However, they should avoid going for the cheapest option as it may not be of good quality.

How to DIY and Replace Gearbox Cooler

It is easier to replace a cooler on one's own than to have it done by a professional. Here are the steps to follow:

• Gather the Necessary Tools and Materials

  One will need tools such as a socket wrench set, pliers, screwdrivers, a torque wrench, an oil drain pan, and a new or refurbished cooler. It is also important to have fresh transmission fluid on hand for refilling after the cooler has been replaced.

• Prepare the Vehicle

  The vehicle should be parked on a level surface, and the parking brake engaged. The hood should be opened, and the cooler's location identified (most are located near the front of the vehicle, close to the radiator). Depending on the design of the vehicle, one may need to access the cooler from underneath the vehicle. In this case, the vehicle should be raised and securely supported with jack stands.)

• Disengage the Transmission Lines

  The cooler is connected to the gearbox by two lines (an inlet and an outlet). These lines carry transmission fluid to and from the cooler. One should carefully remove the transmission lines from the cooler using pliers. Be prepared for some fluid to leak out and have an oil drain pan ready to catch it. Depending on the design, the lines may be held in place with bolts or clips that need to be removed first.

• Remove Mounting Hardware

  One should remove any bolts or other mounting hardware securing the cooler to the vehicle. This may involve using a socket wrench or other tools to reach and remove the fasteners. The specific mounting location and hardware may vary depending on the vehicle.

• Remove the Old Cooler

  Once the mounting hardware has been removed, the old cooler can be carefully pulled out of its location. Take care not to damage any surrounding components or the new cooler during this process.

• Install the New Cooler

  The new or refurbished cooler should be carefully positioned in the mounting location and secured with the previously removed hardware. Be sure to follow the manufacturer's torque specifications for any bolts or fasteners.

• Reattach Transmission Lines

  One should reconnect the transmission lines to the cooler, ensuring a snug and leak-free fit. Depending on the design, this may involve tightening bolts or securing the lines with clips.

• Check for Leaks

  Before starting the vehicle, one should carefully inspect all connections and fittings for any signs of fluid leakage. Address any leaks or issues before proceeding.

• Refill Transmission Fluid

  One should open the hood and locate the transmission fluid dipstick. Remove the dipstick and use a funnel to pour in the appropriate amount of new transmission fluid. Consult the vehicle's owner's manual for the correct fluid type and capacity specifications.

• Start the Vehicle and Check Operation

  One should start the vehicle and let it run for a few minutes. Shift through all gears (P, R, N, D) to circulate the fluid and ensure proper cooler operation. Check the dipstick to ensure the fluid level is within the recommended range. Add more fluid if necessary.

Q&A

Q1: Does the vehicle always need a cooler for the gearbox?

A1: No, not every car needs a cooler for the gearbox. A cooler is not mandatory in most cars with manual transmission. However, any car with a high-performance engine, a heavy load-carrying vehicle, or an area with a hot climate will require a cooler for the gearbox to enhance performance and durability.

Q2: What are the signs of a failing gearbox cooler?

A2: The first sign of a failing gearbox cooler is overheating of the cooler itself. Other signs include a burnt smell like a burnt clutch, oil leaks around the gearbox, bubbles forming on the oil's surface, and visible damage to the cooler or mounting points. However, some of these signs can only be confirmed by an expert mechanic.

Q3: Can one drive with a damaged cooler for the gearbox?

A3: No, it is not advisable to drive with a damaged gearbox cooler. A damaged cooler will either overheat the gearbox or cause it to cache due to a lack of cooling. Both conditions can lead to a fast and expensive gearbox failure. Hence, it is advisable to replace a damaged cooler before driving.

Q4: How long does it take to replace a gearbox cooler?

A4: Replacing a gearbox cooler can take anywhere between 2 hours to 6 hours, depending on various factors. The factors include the vehicle design and model, the location of the cooler, and whether the cooler was changed alongside the gearbox or separately.

Q5: Can a gearbox cooler be installed in a vehicle that doesn't come with one?

A5: Yes, a gearbox cooler can be installed in a vehicle that does not come with one. The installation is highly recommended in vehicles that experience high loads or high speeds, such as sports vehicles or trucks.