Great follow-up, wish I had read it this morning The transmission cooler was what took a lot of my time. That and chasing other leaks since the cooling system is building better pressure with the new radiator.

I've noticed for this repair the Rave manual will have you doing way more work than is necessary, and that the process for removing the grill did not require me to remove any lamp covers (I have an '03). I think in earlier models the turn signals were a separate component, and now it is all integrated into the headlamp housing.

I couldn't get those oil cooler lines off either, and that's when I tried just taking it off in the compartment. Figured out how, and oil mess was avoided!

I did not take the fan off either. Completely unnecessary unless you want the extra elbow room.

The return line is indeed fragile. Mine broke, and I patched it with some rubber tubing. I would like to replace the entire line with rubber tubing.

 

I just picked up a new return pipe at the dealer for 47.95. You can get them on Atlantic British for 36.95. It is NOWHERE near as fragile as my old one. Apparently, over years the hot and cold changes break down the plastic. Mine broke in two places just handling it, so it probably would not be a bad idea to replace this line the first time the coolant is drained after 70k or so.

When I replaced the radiator the t-pipe started leaking at the bleed screw, I barely torqued it initially, and when I torqued it some more (by hand with a screwdriver) the screw broke.

Maybe I jacked something up, but I put another screw in it and it is still leaking, so I'm going to replace the upper hose unit.

The whole unit (upper hoses plus tee-valve) is on AB for around 59 bucks. There's some DIY fabrication of T-valve replacements on this site. I'm not bothering, since this is a daily driver with my kids in it. Apparently these Tee-valves suck so maybe replacing the upper hose unit or tee-valve unit after 70k wouldn't be a bad idea either.

Too much plastic on this cooling system!

 

Edit: Nevermind. I feel dumb but I figured it out. Thanks anyway.

 

The trans cooler lines are not going to come off by just "push - pull" but with a little Pb and some arm muscle nd wiggling, they will. You only have to disconnect the lines on the drivers side FWIW.

 

909wheeler,......what did you push or pull? As you have seen many of us here are stumped by the trans cooler lines. I am trying to get my Radiator out right now,.....and I see that the driver's side trans cooler line and the long metal tab that locks in the radiator, are NOT letting go of the trans cooler. May be different on other years, but my 03 isnt going to let go of the cooler. I will have to undo at least the drivers side trans cooler coupler.

Could you please explain how to twist, push, pull or otherwise do whatever needs to be done to remove it.

Thanks,
BC in Austin