BD Diesel Performance 1030606-5/16 User manual

22 October 2019 1030606 Transmission Cooler Instruction Manual (I-00213) 1
BD Engine Brake Inc.
Plant Address: 33541 MacLure Rd. Abbotsford, BC, Canada V2S 7W2
U.S. Shipping Address: 1124 Fir Avenue, Blaine, WA 98230 U.S. Mailing Address: P.O. Box 231, Sumas, WA 98295
Phone: [phone] | Fax: [phone] | Internet: www.bddiesel.com
DOWNLOAD THE LATEST
INSTALL MANUALS AT
www.bddiesel.com
BD Transmission Cooler
Dodge (68RFE, 518, 47RH, 47RE & 48RE)
Ford (All) & Chevy (Allison) Transmissions
P/N#
1030606-5/16
P/N#
1030606-3/8
P/N#
1030606-1/2
P/N#
1030606-5/8
UPLEASE READ ALL INSTRUCTIONS BEFORE INSTALLATION

22 October 2019 1030606 Transmission Cooler Instruction Manual (I-00213) 2
BD Engine Brake Inc.
Plant Address: 33541 MacLure Rd. Abbotsford, BC, Canada V2S 7W2
U.S. Shipping Address: 1124 Fir Avenue, Blaine, WA 98230 U.S. Mailing Address: P.O. Box 231, Sumas, WA 98295
Phone: [phone] | Fax: [phone] | Internet: www.bddiesel.com
K I T C O N T E N T S
Please check to make sure that you have all the parts listed in this kit before you start
the disassembly of your truck.
Transmission Cooler Base Kit - 1030605
1300601
1300602
1300603-C
Cooler
L Brackets
Wiring Harness
Qty: 1
Qty: 6
Qty: 1
1100110
1100111
1230116
1604104
1110031
1130227
1/4 x 3/4" Bolts
1/4 Washers
1/4 Nyloc Nuts
5/16" x 1" Long Bolts
5/16 Flat Washers
5/16 Nyloc Nuts
Qty: 4
Qty: 8
Qty: 4
Qty: 6
Qty: 12
Qty: 6
1300130
1300131
1300132
1400113
1452821
1300604
Tie Wrap
(Long)
Tie Wrap
(Medium)
Tie Wrap
(Small)
Insulated
Clamp
Gear Clamp
Self-
Threading
Bolt
Qty: 5
Qty: 5
Qty: 5
Qty: 1
Qty:4
Qty:4
15.75
12.75

22 October 2019 1030606 Transmission Cooler Instruction Manual (I-00213) 3
BD Engine Brake Inc.
Plant Address: 33541 MacLure Rd. Abbotsford, BC, Canada V2S 7W2
U.S. Shipping Address: 1124 Fir Avenue, Blaine, WA 98230 U.S. Mailing Address: P.O. Box 231, Sumas, WA 98295
Phone: [phone] | Fax: [phone] | Internet: www.bddiesel.com
1400134
1300620
1400142
1400135
-10/-10 Jic Sweep
Bend Fitting
Temp Sensor
180/160F
-10/1/2” Barb
Sensor Adapter
-10 Jic/ 1/2"Hose
90 Deg Fitting
Qty: 1
Qty: 1
Qty: 1
Qty: 1
3-520338-2
1300337
1607012
1300400
Flag connector 14-
16ga
Mini Fuse
Tapper
Ring Terminal
5/16” 10-12ga
Ring Terminal 3/8”
10-12ga
Qty: 1
Qty: 1
Qty: 2
Qty: 2
5/16” Fitting Kit –1030606-5/16
1400128
1400107
1604054
1/4" NPT / 5/16 Comp
1/4” NPT / 1/2” Barb
1/2" ID Hose
Qty: 2
Qty: 2
Qty: 183”
3/8” Fitting Kit –1030606-3/8
1400105
1400121
1604054
3/8”NPT / 1/2" Barb
3/8” NPT / 3/8” Comp
1/2" ID Hose
Qty: 2
Qty: 2
Qty: 183”

22 October 2019 1030606 Transmission Cooler Instruction Manual (I-00213) 4
BD Engine Brake Inc.
Plant Address: 33541 MacLure Rd. Abbotsford, BC, Canada V2S 7W2
U.S. Shipping Address: 1124 Fir Avenue, Blaine, WA 98230 U.S. Mailing Address: P.O. Box 231, Sumas, WA 98295
Phone: [phone] | Fax: [phone] | Internet: www.bddiesel.com
1600034
1600035
1604044
1604045
Bypass Tube
Eliminator
(Front)
Bypass Tube
Eliminator
(Rear)
Washer
Washer
Qty: 1
Qty: 1
Qty: 2
Qty: 2
*Bypass Tube Eliminators are only required on 4R100 Transmissions*
1/2” Fitting Kit – 1030606-1/2
1400132
1400138
1400136
1604054
1/2” Comp /1/2” Barb
1/2” Sleeve
1/2" Nut
1/2" ID Hose
Qty: 2
Qty: 2
Qty: 2
Qty: 183”
5/8” Fitting Kit – 1030606-5/8
1400131
1400139
1400137
1604054
5/8” Comp / 1/2" Barb
5/8” Sleeve
5/8” Nut
1/2” ID Hose
Qty: 2
Qty: 2
Qty: 2
Qty: 183”
Vehicle Applications
Year
Make
Application
Fitting Tube size
1991-1999
Chevy
4L80
5/16” Tube
1999-2000
Chevy
4L80
3/8” Tube
1993-2012
Dodge (All)
518,47RH, 47RE, 48RE, 68RFE
1/2" Tube
1994-1997
Ford
E40D
5/16” Tube
1999-2002
Ford
4R100
3/8” Tube
2003-2010
Ford
5R110
1/2” Tube
2011-2014
Ford
6R140
1/2” Tube
2001-2010
GM/Duramax
Allison 1000
5/8” Tube

22 October 2019 1030606 Transmission Cooler Instruction Manual (I-00213) 5
BD Engine Brake Inc.
Plant Address: 33541 MacLure Rd. Abbotsford, BC, Canada V2S 7W2
U.S. Shipping Address: 1124 Fir Avenue, Blaine, WA 98230 U.S. Mailing Address: P.O. Box 231, Sumas, WA 98295
Phone: [phone] | Fax: [phone] | Internet: www.bddiesel.com
Optional Temperature Sensors
180 ON / 160 OFF
(comes in kit)
200 ON / 185 OFF
(available separately)
1300620 (black wire leads)
1300621 (orange wire leads)
Before you install your BD Transmission Cooler
If using the BD transmission cooler in extreme cold temperatures
a bypass valve is recommended.
Cooler fan is rated for 66% duty cycle Maximum. Exceeding the
duty cycle may result in voiding the warranty.
The temperature sensor is designed to turn on at 180°F / off at
160°F.
Installation
1) Block wheels of vehicle for safety and disconnect negative battery terminals (record radio settings
before disconnecting the batteries).
2) Using a hoist lift vehicle to access
transmission area.
3) Locate suitable location to mount
transmission cooler. Choose a
location where there will be
adequate airflow through the cooler.
If the cooler is mounted against a
surface ensure there is at least 1” of
clearance behind the cooler and
that it is away from heat sources,
rotating parts and debris.(fig.2)
4) Assemble L brackets and 5/16”
hardware to mount the transmission
cooler to the frame rail. Trim bracket
pieces where necessary, deburr
sharp edges and paint areas that
are exposed to prevent corrosion.
Note: This is a universal cooler that can be mounted in a
variety of locations
1
1300602–L Bracket
2
1604104 –5/16” X 1” Bolt
3
1110031 –5/16” Flat washer
4
1110032 –5/16” Lock washer
5
1130227 –5/16” Nyloc nut

22 October 2019 1030606 Transmission Cooler Instruction Manual (I-00213) 6
BD Engine Brake Inc.
Plant Address: 33541 MacLure Rd. Abbotsford, BC, Canada V2S 7W2
U.S. Shipping Address: 1124 Fir Avenue, Blaine, WA 98230 U.S. Mailing Address: P.O. Box 231, Sumas, WA 98295
Phone: [phone] | Fax: [phone] | Internet: www.bddiesel.com
Fig.2
5) Mount transmission cooler to
bracket (fan side up) with 1/4”
supplied hardware.
6) Mark and drill four 19/64” holes into
frame for self-threading bolts to
mount cooler assembly.
7) Mount cooler assembly to frame rail
using supplied self-threading bolts
and secure with supplied nuts and
washers.
8) Apply small amount of pipe sealant
to temp switch thread and thread
into JIC adaptor until snug.
9) Thread JIC 90deg fittings onto
cooler hand tight. Large sweep tube
fitting connects to outlet.
COOLER
L BRACKET
FAN
Mount cooler along
frame rail or cross
member, away from
rotating pieces or any
heat source.

22 October 2019 1030606 Transmission Cooler Instruction Manual (I-00213) 7
BD Engine Brake Inc.
Plant Address: 33541 MacLure Rd. Abbotsford, BC, Canada V2S 7W2
U.S. Shipping Address: 1124 Fir Avenue, Blaine, WA 98230 U.S. Mailing Address: P.O. Box 231, Sumas, WA 98295
Phone: [phone] | Fax: [phone] | Internet: www.bddiesel.com
10)Thread JIC temp switch adaptor
onto cooler large sweep connector.
11)Locate transmission inlet line (fig 1.1).
Mark and cut transmission line
where the line is completely
straight with no bends or damage
for about 3” to mount compression
fittings. NOTE: Tube attached to
transmission can be rotated for
easy routing of hose.
12)Cut transmission line with pipe
cutter. Deburr inner and outer pipe
edges on both sides.
13)Insert barb-compression fitting onto
cut cooler line ensuring fitting
bottoms out and tighten hand tight.
Then using two wrenches tighten to
crush ferrule 1 1/4 turns.
14)Measure/cut supplied 1/2” hose to
length ensuring hose reaches
cooler from transmission without
being stressed.
15)Install hoses onto barbed fittings
using provided gear clamps and
tighten. (Refer to general hose
routing diagram for general layout.)
Line Position Reference(fig 1.1)
FORD 6R140
DODGE 518, 47RH, 47RE, 48RE
ALLISON
FORD E40, 4R100, 5R110
DODGE 68RFE
INLET
OUTLET
INLET
OUTLET
INLET
OUTLET
INLET
OUTLET
General hose routing (Dodge 518, 47RH, 47RE, 48RE)
FRONT OF
VEHICLE
Pipe Sealant

22 October 2019 1030606 Transmission Cooler Instruction Manual (I-00213) 8
BD Engine Brake Inc.
Plant Address: 33541 MacLure Rd. Abbotsford, BC, Canada V2S 7W2
U.S. Shipping Address: 1124 Fir Avenue, Blaine, WA 98230 U.S. Mailing Address: P.O. Box 231, Sumas, WA 98295
Phone: [phone] | Fax: [phone] | Internet: www.bddiesel.com
16)Tighten all fittings ensuring a
positive connection.
17)Secure hoses with provided tie
straps and insulated clamp.
OEM COOLER
Transmission
Cooler
DODGE 518, 47RH, 47RE, 48RE
INLET
OUTLET
INLET
Using the Compression Fitting
18)Route wiring harness from
transmission cooler along frame
into engine compartment.
19)Under vehicle insert two pin
connector on harness into fan
motor connector, then connect
harness to temperature switch with
blade connectors once appropriate
wire is cut and trimmed to length.
20)Mount relay in a suitable location in
the engine compartment using
supplied self-taping screw.
21)Next trim the wires to length and
crimp the ring terminals to the
BLACK and RED wires.
Connect positive terminal only.
(Driver side battery)
22)Lastly open the fuse box and locate
the 12V ignition switched fuse by
using a digital volt meter or 12V
test light. Remove fuse and install
fuse tapper onto fused side and
reinstall. (5 amp fuse is minimum
requirement)
FAN MOTOR
CONNECTION
NOTE SLEEVE ORIENTATION
WHEN INSERTING INTO FITTING
HOSE
TRANSMISSION
LINE

22 October 2019 1030606 Transmission Cooler Instruction Manual (I-00213) 9
BD Engine Brake Inc.
Plant Address: 33541 MacLure Rd. Abbotsford, BC, Canada V2S 7W2
U.S. Shipping Address: 1124 Fir Avenue, Blaine, WA 98230 U.S. Mailing Address: P.O. Box 231, Sumas, WA 98295
Phone: [phone] | Fax: [phone] | Internet: www.bddiesel.com
23)Cut yellow wire on wiring harness
to appropriate length, strip end and
crimp on supplied flag connector.
Install flag connector onto fuse
tapper. Close fuse box carefully not
to damage wire. (trim fuse box if
necessary)
24)Secure wiring harness to vehicle
using supplied tie straps.
25)Reconnect negative battery terminal with black ring terminal from harness.
26)Start engine, shift through gears manually and check fluid level. Top up fluid with appropriate fluid
type. (Refer to table below)
27)Remove wheel blocks and road test vehicle. Recheck fluid level once vehicle reaches operating
temperature.
FLAG
CONNECTOR
FUSE
TAPPER
FUSE
Mopar

22 October 2019 1030606 Transmission Cooler Instruction Manual (I-00213) 10
BD Engine Brake Inc.
Plant Address: 33541 MacLure Rd. Abbotsford, BC, Canada V2S 7W2
U.S. Shipping Address: 1124 Fir Avenue, Blaine, WA 98230 U.S. Mailing Address: P.O. Box 231, Sumas, WA 98295
Phone: [phone] | Fax: [phone] | Internet: www.bddiesel.com
Wiring Diagram
If you have any technical difficulties, concerns, comments, or complaints,
please phone our Technical Support hotline at [phone] between
8:30am-5:00pm PST (Pacific Standard Time) Monday to Friday.
20A Fuse