mdweiss

Ok guys I’ve had my car for about 2 months and it’s finally time to start modding the motor.

I have a 2003 and I have read a lot about the radiator issues that allow coolant to leak into the stock transmission cooler and can ultimately kill the tranny. It looks like this problem was up to production date of 9/2003 and my car is a 4/2003 and sure enough after removing the core support to check, I have the bad “Valeo” brand radiator.

So I could wait it out and maybe never have an issue or I could fix the potential leaking before it becomes a problem. I did a fast online search and found the prices on radiators to be pretty steep. So I decided to just add an external, larger aftermarket tranny cooler to fix my problem and to get an upgrade out of it. It also happened to cost me about 25% of what the radiator was going to cost.

You will notice I removed the heat exchanger too, more on that later

I started off by taking the bumper off the car to see what I had to deal with…






I needed to remove the horn (I relocated it in the bumper) and to bring the power steering cooler forward to allow the new cooler to clear.
Just to get an idea of how everything was going to fit I zip tied everything in place.


I installed a foam strip on the backside of the new cooler to seal against the condenser, and made 2 brackets to support the cooler from the bumper. Notice the stainless and rubber clamps holding the power steering to the cooler.




Next I had to tackle the fittings, I went to my local fitting guys and they would have had to order the Mercedes style fitting, so I bought 2 -6 AN weld on fittings and removed the stock hard lines and made my own adapter fittings. I also welded the radiator side of the hard lines shut and reinstalled them, just in case the internal core fails in the future I won’t have coolant leaking. I then added some heater hose to keep the lines from future damage.

mdweiss

Now that I had the cooler in I decided to tackle the heat exchanger, I wanted to do this all at once because removing the bumper more than I need to is asking for trouble.

The core is huge and im very happy with how it turned out. I tapped the holes in the upper tabs, and cut the lower ones off. I then made 2 notches and 2 holes in the bumper to allow it to be installed. I also needed to remove the overhanging lip on the bumper, but in the end it turned out great and is super strong.

From frozenboost.com






The bumper needed almost no trimming and the drain is usable with the removal of the small underbody tray.





There is more to come, I’m going to be making and installing an external reservoir somewhere other than the trunk, I don’t want to lose my storage. Then ill split the cooling circuit, but I’m a firm believer that splitting it without an external reservoir is more harm than good. Ill make another post when that time comes

BenzoBoi

For the external reservior, stick it under the trunk where the spare tire would go. I have an 03 too and it didn't come with a spare so I put it there. That way you can still utilize your trunk!

Excuse the mess...

mdweiss

"I’m going to be making and installing an external reservoir somewhere other than the trunk, I don’t want to lose my storage."

if all else fails and i cant find a location ill think about the trunk

is that a cobra reservoir? and water meth injection? it looks good

thanks

BenzoBoi

I read what you wrote above. I suggested the spot because I, like you, need my trunk space. If you have it where I suggested, you can still fully utilize your trunk space. I doubt you will enough room to fit a decent sized reservoir anywhere other then below the trunk. If you can kudos to you. . Thanks for the kind words on my setup. It isn't as bling as others but I have been running this setup for about a year now.

shardul

iTrader: (1)

thank you for the write up mdweiss. I wanted to see if the cxracing heat exchanger would fit our cars. it is a nice inexpensive upgrade.
Have you data logged to car to see what the IATs are?

SterlingE55

Very Nice! That E63 bumper and CF lip look SICK! So do the wheels. Got any pics of the whole car? Great install. I like that you painted it black so it's stealthy.

SterlingE55

Which HE is that? I doesn't look like the one on cxracing.com.

Yacht Master

Pretty work! Moderators should sticky

reitmeid

That H/E is from Frozenboost

reitmeid

Nice installation, great idea. I have an 03 also, but since I live in Mn, I don't think your solution would work for me. Driving around at 10 to 30 degrees and colder, I don't think the tranny fluid would ever warm up sufficiently. I guess when I install the H/E I just ordered, I'm going to go with a new radiator so I can put the transmission worry away once and for all.

TopGun32

very nice write up!

I have an 03 and built before they changed to the new radiator, but I do have a service invoice from my dealer where they performed glycol test and found no issues.

But its better to be caution I guess.

That H/E is very stealthy.

mdweiss

thanks guys, Yes the core is from frozen boost. I didn't do any iat test as I know its going to help. Its the largest unit that I can fit, so regardless of the numbers I can't make it any better.

I'll have to upgrade my sig and post full pics one of these days

soundeffects

I had my transimission replaced before I bought the car because of the radiator leak your talking about. When they put a new tranny in, they also put in a Heat Exchanger and a tranny cooler in the same place. Works good without any issues.

reitmeid

I'll bet the auxilliary tranny cooler in your car works in conjucntion with the stock radiator tranny cooler.

soundeffects

I'll have to check again. I know they put in a new radiator from a newer year E55 if I recall

IMPORTIMAGE

im liking the trunk setup, makes me want to install a trunk mount meth kit in my car...

its much easier when companies sell kits.

nice write up.

mdweiss

im in the middle of adding a trunk reservoir, ill post pics when its done

chawkins2001

subscribing

V12Godspeed

Very nice set up.

MB_Forever

One year old thread

chawkins2001

I know, worth a bump though for some good content

tbal

Reviving from the dead...

So that He from frozenboost... was this one http://www.frozenboost.com/product_i...0b4fee25778e3a (CHEAPP!!) Has anyone else done this upgrade?

Daniel247

After 247000 kms my transmission fluid got contaminated. Car is sitting at dealer with a $10K repair quote. Not impressed. The above post has made me breathe again. Thank you very much gentlemen. I will proceed in same way.

Regards

Benzor1

Wondering if anyone knows was aftermarket trans cooler was used here? Great writeup, I'm trying to figure this out myself.