Finally got to install the 6.0 transmission cooler on the 96 f250 7.3. Wasn't complicated, just time consuming. I pulled the grill and all associated parts off the front end. On a 17 year old new england truck, plan on breaking bolts and working to get others off. Those side marker lights are fun to get off. Here is a good link showing how
https://www.ford-trucks.com/forums/1...ll-w-pics.html

I removed the driver side battery tray and made it so much easier.

here she is, front stripped. You can see the nice rusted sections of the rad core support.
if you look close to the upper left of the core support opening you can see the massive stock trans cooler.
You will need to cut the vertical metal upright that is in the center. I unbolted the latch and cut it then bolted the latch back on.

closer shot of the rust and missing metal

for the lower bracket, I used some 2x2 angle, cut in an inch wide strip

then I took some straight stock to extend from the L up to the mounting bracket on the cooler.

here it is bolted up

for the hose connection I got this. The threaded end fits snuggly into the 1/2" hose and it reduces to 5/16". I put some the black rtv sealant on the threads to stop the transmission oil from following the threads an leaking out. Then put a clamp around it

here it is mounted up. for the upper mounts I had some metal tube I just cut to length and ran a long bolt thru. Drilled new holes into the rad support and radiator mounting flange. The cooler is mounted high so the top is just behind the latch. I adjusted the space at the top so the cooler wasn't touching the a/c cooler or the latch, but only looking at 1/8-3/16" on either side. The hose routing, I followed the original but be careful because the hose will kink if the bend radius is too tight. The passenger side is probably about as tight of a bend as it will take. I ran the hose coming out of the radiator cooler to the driver driver side of the cooler and the passenger side is connected to the return to transmission line. Just the way I wanted to do it.

I also had some larger rubber hose that I used as a protective sheeve over the 1/2" hose for areas that looks like there may be rubbing. I am not sure what it was from but it had some preformed bends that worked good.

Drove it around some yesterday,4 short trips of 10-12 miles for a total of 45-50 miles. Air temps probably low 80's. Highest temp for trans was 130 I saw. Typically I would see 80-100 degrees above ambient. So far no leaks. Will be pulling our 7K+ travel trailer wednesday.

 

Thanks for taking clear pictures, I've picked one of these up for my Bronco, but couldn't picture the mounting...

 

Thank you.

Yours will be a little different because the radiator core support doesn't drop below the frame rails like it does for the diesels