Last fall I installed an electronic gauge set that can display the various temperature sensor values in the engine and transmission, as well as an exhaust gas temperature probe (EGT) on our `05 diesel.
In a test drive after doing this I finally saw how hot everything was getting. A 20deg F day while driving up a hill at about 40mph had the transmission temperature hit about 205deg, the EGT got up over 1000deg, and the engine temperature was about 220.
This seemed quite excessive, and a quick check of our power-steering fluid (which doesn't have a temperature sensor) revealed definite burning.
That data, coupled with the consideration that often we are driving very slowly in hot temperatures (think Moab trails in the summer) would tax the cooling systems even more (no airflow, hot air for cooling, etc).
The contributory issues appeared to be many: First the transmission cooler is tiny (1/6 the size of the one in the F350 of same vintage), and located right behind the FORD emblem on the grill. The power steering cooler is tiny. We have an Aluminess bumper which blocks the lower 1/3 of the radiator stack for AC, coolant, and intercooler. Finally, the van engine compartment is packed and cramped, with nowhere for incoming air to go, so this builds high-pressure in the engine keeping cooling air from flowing through the radiator stack as easily.
The solutions we chose were these: Remove stock grill and replace with a relatively sparse metal grill for more airflow. Trim away all of the excess bracing and plastic around the radiators that we no-longer need to allow more airflow. Replace the transmission cooler with one over 2x as large. Replace the power-steering cooler with the old transmission cooler. Put louvers on the hood and quarter-panels to let hot air out. Auxiliary electric cooling fans mounted to both the transmission and PS fluid coolers, and triggered by thermal switches mounted on the intakes to the coolers @ 180deg.
I have seen some folks put a scoop under the front bumper to pull air up into the lower part of the radiator stack at speed, but this won't work for us as we currently have an extra cross-frame member here for rigidity and holding a front receiver. Additionally this won't do much when the forward speed is just a few miles per hour, which is when I think we are probably torturing the cooling systems the most.
Here is a view of the front of the van with the new transmission cooler (left), and steering fluid cooler (right). Also note how the lower 1/3 of the larger coolers would be covered by the front Al bumper.
And here is a view of our hood and quarter panel with the new vents and grill in place.
After putting all of these changes in place I did a test drive on the same hill on a 10deg warmer day and found the transmission temperature just sat at 170 (the thermostat temp), the EGT never exceeded 950deg, engine was at 205deg, and the power-steering fluid hit a high of 80deg after 30 min of in-town driving.
At a pull-off on the road I hopped out and could feel hot air gushing out of all 4 of the louvered vents.
More pics & details at our webpage
http://www.badgertrek.com/sportsmobi...l#Transmission
-e
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