Derale 20561 User manual

INSTALLATION INSTRUCTIONS
DIRECT FIT TRANSMISSION COOLER
PART # 20561
(Page 1)
Please read these instructions completely before beginning installation
KIT CONTENTS
QTY. DESCRIPTION
1 Cooler Assembly
1 Inner Frame J Bracket
1 Outer Frame C Bracket
1 Cooler Feed Hose
1 Cooler Return Hose Assembly
4 Double Hose Support
1 Thermostat Switch
1 In-Line Thermostat Housing
12ft Black Wire Loom
12ft RED Wire
QTY. DESCRIPTION
1 5/16”-18 x 5” Bolt
1 5/16”-18 x 1 1/4” Bolt
1 5/16”-18 x 1” Bolt
6 5/16” SAE Flat Washers
3 5/16”-18 Lock Nuts
3 1/4”-20 x 3/4” Bolts
3 1/4” SAE Flat Washers
3 1/4” Star Washers
3 1/4”-20 Lock Nuts
2 Stainless Hose Clamps
QTY. DESCRIPTION
4 Plastic Mounting Rods
4 Plastic Retainer Clips
8 1 x 1 Foam Pads
1 20 Amp Fuse Holder
1 Blue Wire Splice Connector
1 Blue Butt Connector
2 Blue Female Connector
1 Blue Ring Terminal
1 #10 Sheet Metal Screw
4 6” Zip Ties
12 4” Zip Ties
IDENTIFYING COMPONENTS
APPLICATIONS
1987-1996
Jeep
Wrangler YJ
1997-2006
Jeep
Wrangler TJ
Thermostat Switch (1)
Plastic
Mounting Rods (4)
Plastic Retainer
Clips (4) 1 x 1 Foam
Pads (8)
Inner Frame Bracket
(J-Bracket) (1)
Outer Frame Bracket
( -Bracket)C (1)
Cooler Assembly (1)
Cooler Feed Hose (1) Cooler Return
Hose Assembly (1)
Double Hose
Support (4)
In-Line Thermostat
Housing (1)
Black Wire Loom
(Convoluted Tubing) ( )
12ft
RED Wire (12ft)
5/16”-18 x 5” Bolt (1)
5/16”-18 x 1-1/4” Bolt (1)
5/16”-18 x 1” Bolt (1)
1/4”-20 x 3/4” Bolt (3)
5/16” SAE Flat Washers (6)
1/4” SAE Flat Washers (3)
1/4” Star Washers (3)
5/16”-18 Lock Nuts (3)
1/4”-20 Lock Nuts (3) 20Amp Fuse Holder (1)
Stainless
Hose Clamps (2)
Blue Wire Splice
Connector (1)
Blue Butt
Connector (1)
Blue Ring
Terminal (1) 6” Zip Ties (4)
4” Zip Ties (12)
#10 Sheet
Metal Screw (1)
Blue Female
Connector (2)

PRE-INSTALLATION
1. Using a flat table or workbench, lay the Cooler Assembly on a flat
surface (Electric Fan facing up as shown in Section: Identifying
Components).
1. Identify the In-line Thermostat Housing and the Thermostat Switch.
2. Using Loctite or a suitable sealant, carefully screw the Thermostat
Switch into the In-line Thermostat Housing turning the switch
clockwise. (Hand Tighten Only) See Diagram #1
DO NOT USE A WRENCH TO TIGHTEN THE
THERMOSTAT SWITCH; OVERTIGHTENING WILL
DAMAGE STUD AND VOID WARRANTY.
1. Identify the Inlet Port on the Cooler Assembly. When facing the ports
on the cooler it will be on the right side. See Diagram #2
2. Take the In-line Thermostat Housing and Thermostat assembly and
identify the female threads. Carefully screw the female side onto the
Inlet Port of the Cooler Assembly. See Diagram #2
3. Using a 7/8” wrench and a 1-1/16” backup wrench tighten
Thermostat Housing.
THERMOSTAT INSTALLATION
WARNING:
Diagram #1
Thermostat
Switch In-Line
Thermostat
Housing
CAUTION
Silver/Red
Label
Positive Wire: Black
Serial No.: 000000232446
AIRFLOW
Customer P/N:
Diagram #2
Inlet Port
Blue Female
Connector(s)
Red Wire
Black Wire Loom
(Red Wire Inside)
To Chassis
Ground
PRE-INSTALLATION (Continued)
IDENTIFYING THE POSITIVE & NEGATIVE WIRES ON THE ELECTRIC FAN
PRE-WIRING THE COOLER ASSEMBLY
1. Locate the Red/Silver label on the Electric Fan. See Diagram #3
2. This label identifies the airflow direction and the color of the Positive Fan wire. In this application the positive wire can be the
black wire so make sure to check label.
3. Once you have determined the color of the positive and negative wires continue with the following steps, Pre-wiring the
Cooler Assembly.
1. Take the 12 feet of RED Wire and 12 feet of Black Split Wire Loom supplied.
2. Install the RED wire into the Black Wire Loom
3. Using a Blue Butt Connector supplied, attach one end of the Blue Butt Connector to either end of the RED wire using the
proper crimping tool. See Diagram #4
4. Attach the Blue Female Connector to EITHER terminal on the Thermostat Switch. See Diagram #4
5. Using a Blue Butt Connector supplied, attach the Blue Female Connector to the Positive Wire on the Electric Fan. See
Diagram #4
6. Attach the Blue Female Connector to the remaining Thermostat Switch wire. See Diagram #4
Diagram #3 Diagram #4
Thermostat
Switch &
In-Line
Housing
(Page 2)

Frame Rail
Bolts, Washers,
Star Washers & Nuts
Outer Frame C Bracket Frame Rail
Drivetrain
Cooler
Assembly
Inner Frame J Bracket
Exhaust
Skid Plate Rear Tire
VEHICLE INSTALLATION
COOLER LOCATION
VEHICLE PREP
The Cooler Assembly mounts on the drivers
side frame between the rear trailing arm and the
transmission/transfer case skid plate. See
Diagram #5
1. Park vehicle on a solid, level surface and
allow vehicle to completely cool before
beginning installation.
2. Disconnect Positive lead on the vehicles
battery.
3. With the transmission in park, engage the
emergency brake. Carefully raise the
vehicle using the appropriate floor
jack/lifting device.
4. Properly place four jack stands, one for
each corner of the vehicle. Refer to the
vehicles owners manual for the proper
lifting locations.
Diagram #5
MOUNTING THE COOLER ASSEMBLY
1. Identify the Inner Frame J Bracket and the
Outer Frame C Bracket.
2. Identify the following hardware, (1) 5/16-18 x 5” Bolt, (1) 5/16-
18 x 1 1/4” Bolt, (1) 5/16-18 x 1” Bolt, (6) 5/16 SAE Flat
Washers, (3) 5/16-18 Lock Nuts
3. Take the Inner Frame J Bracket. The longer leg sets on the top
of the vehicles frame allowing the shorter leg to butt up against
the side of the frame just below the vehicles fuel/brake lines.
See Diagram #6
4. Take the Outer Frame C Bracket. This bracket slides from the
outside of the vehicles frame over the top of the Inner Frame
Bracket and around the vehicles frame. See Diagram #6
5. Using a 5/16” SAE Flat Washer, take the 5” bolt and install it
into the bottom hole closest to the vehicles frame sliding it all
the way up through the inside upper hole. Install a 5/16” SAE
Flat washer and 5/16-18 Lock nut on the top of the bracket
assembly and hand tighten. See Diagram #6
6. Using the 5/16-18 x 1” Bolt, SAE Washers, and 5/16-18 Lock
Nut, install this bolt in the upper outside hole and hand tighten.
7. Using the 5/16-18 x 1 1/4” Bolt, SAE Washers and 5/16-18
Lock Nut install this bolt in the bottom outside remaining hole
and hand tighten. See Diagram #6
The frame brackets can be moved forward or back
along the frame to assure clearance of the Cooler Assembly.
8. Identify the following hardware, (3) 1/4-20 x 3/4” Bolts, (3) 1/4”
SAE Flat Washers, (3) 1/4” Star Washers, (3) 1/4-20 Lock Nuts
9. Take the Cooler Assembly and hold it up to the Inner Frame
Bracket Assembly and Install 1/4-20 Bolts, Flat Washers, Star
Washers and Lock Nuts as shown in Diagram #7
Cooler Assembly has a built in pivot mounting
system. This will allow you to pivot the cooler to not only clear
all vehicles obstructions but to allow you to improve airflow on
vehicles with extra body clearance. Always adjust Cooler
Assembly with the maximum angle without touching any of the
vehicles components.
10. Once Cooler Assembly is in the desired location, be sure to go
back and tighten all mounting hardware.
Outer Frame C Bracket is designed to bend up against
the Inner Frame J Bracket causing a clamping effect.
NOTE:
IMPORTANT:
NOTE:
(Page 3)
Diagram #7
Frame Rail
Inner Frame
J Bracket
Outer Frame
C Bracket
5/16-18 x 1”
5/16-18
x 1-1/4”
5/16-18 x 5”
Factory Fuel/
Brake Lines
Diagram #6
Forward Mounting Back Mounting

Engine
Radiator
Remove Factory
Transmission Return Hose
Fan Shroud
Pulley
Engine
Radiator Cooler Feed Hose
Cooler Return Hose Assembly
Fan Shroud
Pulley
Plastic Hose Connector
VEHICLE INSTALLATION (Continued)
COOLER HOSE INSTALLATION
1. Identify the Cooler Feed Hose and the Cooler Return Hose
Assembly. Both hoses have one end with a 90 degree fitting.
2. Take the Cooler Feed Hose and install the 90 degree fitting
onto the Inlet Port of the Cooler Assembly. See Diagram #8
3. Take the Cooler Return Hose and install the 90 degree fitting
onto the Outlet Port of the Cooler Assembly. See Diagram #8
4. Route both hoses together and along the inner frame rail of
the vehicle. See Diagram #8
5. Identify the following hardware, Plastic Mounting Rods, Plastic
Retainer Clips, Double Hose Support, 1 x 1 Foam Pads and
6” Zip Ties.
6. Using Diagram #9 as a reference, Insert a 1 x 1 Foam Pad
onto the Plastic Mounting Rod sliding the tip of the rod thru
the factory Fuel/Brake lines.
7. Install another 1 x 1 Foam Pad, Double Hose Support and
finally a Plastic Retainer Clip. See Diagram #9
8. Install the two hoses running along the frame into the Double
Hose Support.
9. Cinch the Plastic Retainer Clip until completely tight slightly
compressing the foam pads.
10. Cut excess mounting rods.
11. Use the 6” Zip Ties to secure hoses in areas making sure
hoses are away from Hot or moving obstructions.
12. Repeat steps 5-10 along the frame rail up to the front of the
vehicle.
13. Route hose up to the bottom of the vehicles radiator.
14. Disconnect the factory rubber transmission return hose from
both ends and remove. One end-radiator fitting, Other end-
Steel Transmission Line. See Diagram #10
15. Install a Hose Clamp supplied onto the Cooler Return Hose
Assembly. Connect the short hose coming off the 180 degree
fitting to the existing transmission line and tighten clamp. See
Diagram #11
16. Install a Hose Clamp supplied onto the Cooler Feed Hose.
Connect the hose onto the existing radiator fitting and tighten
clamp. See Diagram #11
17. Route Cooler Feed Hose to the bottom of the engine fan
shroud and install in plastic hose connector. See Diagram #11
(Page 4)
Factory Fuel/Brake
Line Brackets
Plastic
Mounting
Rod
Foam Pads
Double Hose
Support
Plastic Retainer
Clips
Frame
Rail
Diagram #9
Diagram #11
Diagram #10
Frame Rail
Cooler
Assembly
Cooler Return
Hose
Cooler Feed
Hose
Factory Fuel
Brake Line
Brackets
Black Wire
Loom
Double Hose
Support
Zip Tie
Outlet Port
Inlet Port
Diagram #8

Warning: Installation of accessories should only be undertaken by those with mechanical knowledge and are familiar with working on
vehicles. Always use eye protection (goggles, safety glasses or shield). Park the vehicle in a well lit area, on level ground and apply the
parking brake. Only work on a cold vehicle that has been sitting overnight, failure to do so will result in severe burns and injury. Before starting
the vehicle, make sure no tools or any other items are left under hood that could interfere with or be drawn into moving parts of the engine.
Failure to follow instructions can lead to severe damage and personal injury.
(Page 5)
VEHICLE INSTALLATION (Continued)
WIRING THE ELECTRIC FAN
1. Locate the negative wire on the electric fan. Look in the area
of the Cooler Assembly along the vehicles frame or body and
locate a good chassis ground.
2. Identify the Blue Ring Terminal Supplied.
3. Use the proper crimping tool; install the Blue Ring Terminal
onto the Ground Wire of the electric fan.
4. Using the #10 Sheet Metal Screw supplied, install the
negative wire.
5. Route the Black Wire Loom with the Red wire inside along
the vehicles frame up to the vehicles firewall.
6. Using the 4” Zip Ties supplied attach the Black Wire Loom to
the vehicles fuel line underneath the new transmission cooler
hoses. See Diagram #12
7. The Red wire needs to be connected to the vehicles switched
ignition source. An ignition source can be found in a few
locations. 1. Under the dash 2. In the vehicles fuse box.
8. Using a test light identify a switched ignition source. Route Red wire to the ignition source.
9. Using the 20 amp fuse holder, Blue Butt Connector and Blue Wire Splice Connector supplied, install Red wire onto the
switched ignition wire.
Wiring fan directly to a 12V constant source will allow the fan to run after the vehicles ignition switch has been turned off.
It is recommended to always use a switched ignition source.
1. Reconnect the positive battery cable
2. Carefully remove the jack stands and lower vehicle onto a flat surface.
3. Before starting vehicle, add 1 quart of fluid into the transmission.
4. With the parking brake applied, start vehicle and shift transmission several times from reverse to drive and then back to
Park.
5. Check the transmission fluid level and add fluid as needed.
1. Inspect all hose connections for leaks.
2. Drive vehicle 1-2 blocks and then recheck fluid levels.
3. Let vehicle completely warm up and then check to make sure electric fan turns on. Please note that it may take some time
for cooler to warm up enough for electric fan to start. Driving vehicle several miles may be required.
Note:
AFTER INSTALLATION
SYSTEM CHECK
Frame Rail
Cooler
Assembly
Cooler Return
Hose
Cooler Feed
Hose
Factory Fuel
Brake Line
Brackets
Black Wire
Loom
Double Hose
Support
Zip Tie
Outlet Port
Inlet Port
Diagram #12
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