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diff cooler anyone? FC

Old 10-15-08, 10:13 PM
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diff cooler anyone? FC

As you may or may not know, the pumpkin housing on a naturally aspirated fc isn't very big. Unfortunatly my dumbass didn't swap a T2 drive train in when I turbo'd my car and when it came time for me to get a differential put in the issue arose. I'm rocking a 1.5 way Kaaz unit and it's working magic but the fluid heats up way too fast. I had talked with a Kaaz engineer and he said I should consider running a diff cooler. Same premise as the oil cooler but basically for the diff. I have a cooler picked up from summit, with an attached electric fan, I have a spot to mount the cooler I just need someone to reccomend an inline fluid pump aswell as maybe what I could do about getting fittings that would allow hoses to be hooked up to the diff fill and drain plugs. keep in mind the pump needs to be able to handle super hot fluids. Thanks
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Old 10-15-08, 10:46 PM
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Tilton makes pumps for just that purpose. As for the fittings, you'll probably have to measure them to figure that out.
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Old 10-16-08, 10:08 AM
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Thanks buddy, I found a Tilton on summit for $179. I was hoping it'd be a bit cheaper but whatevers. So with the cooler and the pump I'm just under $300 not bad. I just need to figure out how to plum the lines from the diff. The pump takes 7/8 NPT and the cooler itself uses barbed ends so hose clamps should be adequete. I will update!
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Old 10-16-08, 12:36 PM
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Spend the extra money and use earl's/aeroquip fittings if you can, you'll be happy you did the first time you don't DNF because of a failed fluid coupler.
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Old 10-16-08, 02:09 PM
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I'm really interested t see where you mount the cooler and how you route everything. I've been looking at this project for a while, thought I won't have reason to do it for some time.
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Old 10-16-08, 05:45 PM
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I used Genesis pumps from Hoerr Racing Products, at $179 each, for tranny and diff coolers for a rotary Miata. Definitely plumb everything with braided lines, try to tuck all the lines as high up as possible to prevent bent or broken lines when you have an off track experience. Also, consider suspension travel, moving suspension parts, and missiles that will be thrown up by the tires.
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Old 10-16-08, 07:43 PM
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Good pointers gents, I will be sure to take notes. As for placement I had planned on using the left side of the gas tank where the muffler used to be. I'll draw something up in MS paint really fast to give a rough idea.
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Old 10-16-08, 08:06 PM
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Let me explain this picture a little bit haha, it looks like my little sister made it.

Basically, the underview is just to show placement on the car, not how the cooler itself would be posistioned. I'm not sure if it'd be adequete protection or not but I still have the heat shield from the stock exahuast right there so that could offer some degree of isolation from side contact or debris coming off the tire.

My only concern now when mounting it is should I stand it up or mount it flat? That picture was my idea to mount it flat. Space it maybe half inch or so from the chassis and put a scoop shroud that directs air flow throw the cooler and out through the spacing. I don't imagine this thing will need crazy air flow especially since it has a fan on it but I'm sure it only helps.



heres the cooler unit I picked out
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Old 10-17-08, 11:03 AM
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Be sure to put a in-line oil filter before the pump. Otherwise the metal particles and chunks in the oil will destroy the pump.

http://www.petersonfluidsys.com/filter_oil.html
600 Series w/ Temperature Port
Peterson's 600 Series filters have been used successfully by Winston Cup teams to filter rear end and transmission lubricants. This filter incorporates our 100 micron element and an end cap that accomodates a temperature sensor.
09-0631 -8 AN Filter with temperature Port. 100 Micron

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Old 10-17-08, 11:42 AM
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I think with the additional oil volume in the cooler/lines and pump as well as the fact that you have the built in fan, you should not have problems with cooling.

You are most likely going to have to compromise between good air flow and not knocking parts of when you have an off track. My experience is the better air flow, the more exposed the system is to being damaged.

Good call on the filter, I like that with the built in temperature port.
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Old 10-17-08, 08:25 PM
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I'd put it in the best protected position you can and let the fan worry about the airflow.
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Old 10-20-08, 11:47 PM
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Worrd so it seems like I've got a winnng combination. Now for the tricky part...can anyone tell me what how where maybe I could get banjo bolts the same thread and pitch as the diff fill and drain plugs? Or is that something I local shop could do? If not banjo, an fittings would be ideal...
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Old 10-21-08, 10:23 AM
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The drain plugs should be pipe thread, (npt) I know aeroquip, makes a "npt" to "an" adapter, as I bought them for my Miata.
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Old 10-21-08, 01:59 PM
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Since my rear end is N/A and the differential is actually a Kaaz for the Miata I'd assume they should be the same right?
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Old 10-21-08, 02:23 PM
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I believe I found the pieces you're talking about on summit, something like this?



anyone able to get me the sizes for these bad boys?
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Old 10-21-08, 08:28 PM
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That looks to be the one.
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Old 10-22-08, 09:06 PM
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goodstuffs. I might have to hop on a miata forum or something to see if I can get the size of that bolt or wait until I get back in the states to take my own somewhere.
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Old 10-22-08, 09:10 PM
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I had the same kind of thought for how to plumb that cooler into the diff, but how would you fill it enough to make sure that you had fluid in the entire system plus the right amount in the diff? Purge it really quick into a bucket or something?

Sounds like youve got everything kinda figured out. Interesting topic.
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Old 10-22-08, 10:21 PM
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Sorry, danegerous I did not read your whole post. The adapters will thread into the oil drain and fill plug holes. The car is not at my house and I can not remember what the bolt size is, I will check tomorrow. Put the bottom adapter in, connect the line and then fill with oil in the top drain plug. Run the pump to fill the cooler and lines and then top off the oil level. Use "full swivel" fittings to connect to the adapter, it will make it easier to connect.
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Old 10-23-08, 10:57 AM
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Alright, I am an idiot. You want an 18 mm by 1.5 adapter, not pipe. Aeroquip makes them in dash 6 and dash 8 sizes.
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Old 10-23-08, 11:07 AM
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looks like its coming along

i have been wanting to doing the same setup but i have no money for side project to the car right now
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Old 10-23-08, 01:38 PM
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Nice! thanks again without your advice chedstar this would be pointless. I haven't ordered anything yet as I'm going to lay it all out, measurements and everything before I start but you guys have my word once I'm back in the states I will put this plan into action.

So far spending is about $310 which includes

tilton trans/differential pump $180
Oil cooler unit $110
6 an fittings (2 for diff, 2 for filter, 2 for cooler) $20

still need:
braided/stainless lines fabbed (not too spendy at your local hose shop)
filter ( I like the peterson unit for the temp sensor port but I'll list an alternative


once again, input, advice, opnions always appreciated!
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Old 10-23-08, 01:56 PM
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The fittings are a lil more expensive then I had listed... I think we should go with -8 an fitting, simply because the cooler unit itself's inlet/outlet is 1/2''. We're gonna need an NPT adapter cause the pump is 3/8 inlet outlet...and I'm having some trouble locating a filter...even the peterson one listed by drivefast. I'll update once I source all the fittings and hopefully a filter.
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Old 10-23-08, 02:34 PM
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done and done
---------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------
2x 3/8 npt to -8 an fittings $6 ( pump to cooler lines)
4x 18mm by 1.5 adapters $32 (diff to filter, filter to pump, cooler return to diff)

which brings our total to $330, minus the lines and filter.

Another concern is how do you hook up an lines to the cooler unit? It's just a barbed end...is there anything to do about that or are hose clamps going to have to cut it?

One more layout to show where the fittings are needed:
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Old 10-23-08, 03:26 PM
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Where did you wind up sourcing everything from?

-Trent
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