Leaky SOBs. I came up with a solution for these leaky transmission and oil cooler quick connects that allows their reuse. In my LS swap I removed all four quick connects, and upon reconnecting them they all leaked. They leak from the compression fittings and from the o-rings that are inside the connectors. No wonder really as they are 22 years old. So here is what I did. First I cut the old compression fittings off with a Dremel tool. Once those compression fittings were removed, the quick connect with its ****** end can be refitted with new transmission hose and new hose clamps. Notice I used actual transmission cooler hose, and not fuel or heater hose. The hardest part of this repair was finding the correct size of O-rings. I carefully measured the original, 22 year old o-rings. The cross section of the originals was 2.3 mm on one side and 2.8 mm on another side, and more oval in shape than round. The original O-ring cross sections had also developed flat spots. The inside diameter of the o-rings was about 14 mm, so I hoped the 2.5mm X 14mm o-rings in a couple of the kits would work, but unfortunately the sizes shown are NOT accurate. Many of the supplied o-rings are actually smaller than described. In the 4th picture you can see I bought at least 4 sets of O-rings.
In the 5th photo you can see the o-rings that ultimately worked. Both are nitrile rubber, but in different colors. The green ones are the ones I chose to install. In photo 6 you can see the measurements of the original o-rings and two potential replacements. The replacements really needed to be larger than 2.5mm in cross section and slightly smaller than 14 mm in inside diameter. Both of these choices would probably have worked fine.
Photos 7 and 8 show the Amazon listing for the green o-ring kit and “The O-ring Store” packaging, which shows their website. The O-ring Store’s O-rings are purchased individually for about a dime, but shipping was $10, so the Amazon kit was a better value at $8 with free Prime shipping.
Photos 9 and 10 show the green O-rings in place. Be aware there is a plastic washer between the O-rings that needs to stay in place when you remove the old O-rings….you can’t really see this plastic washer in the photos. I used a steel pick to remove and replace the O-rings. Easy.
After replacing the O-rings I applied a smear of motor oil on the O-rings and reinstalled in the Disco, and no more leaks. Net cost for me was about $50 because I bought 4 kits worth of O-rings to try. If you buy just the green set of O-rings or buy the correct size from The O-ring Store, your cost will be $8 to $12. Half inch transmission cooler hose can be picked up at most auto parts store at $7 or $8 a foot.
A note on the green O-rings….the size I used was shown as 9/16 X 3/32 OR 13.95mm X 2.62mm. These two descriptions are NOT the same size….I think you literally receive one size or the other. The size I received was much closer to the metric size, and that’s why I used that size.
Alternatively, you can buy new hose assemblies for several hundred dollars. I prefer to rescue old parts when I can. I bet I’ll get more than 10 years out of my repairs.
Good luck with yours.

 

Excellent!

 

This is perfect! Mine been seeping since forever

 

This is fantastic! Thank you!

 

You got my hopes up there for a minute!! And a sticky no less!! In the northeast we have a different problem with those POS connectors. The barrel corrodes to the point that the plastic collar no longer slides in either direction. If/when you do get it to move, the build up of rust in there prevents the plastic from putting any real pressure on the metal fingers and they don't retract inside the fitting. It's a real conundrum. I've replaced the internal seals with the factory parts plenty of times (ESR1594L, typically about $1/ea) and have never had problems with any leaking after the fact, but that's only when I can get those bullsh!t connectors apart in the first place. Careful installation and making sure there's positive engagement of the internal locking clips is the most important part, and yes, refreshing the seals whenever apart is all you really need for successful repair. I did a radiator in an 02 over the weekend which had a trans and an oil cooler and was dreading having to do battle with the fittings. Luckily I was able to do the job without having to disturb any of them. These rusty things are diabolical.




This is another classic example of something that makes manufacturing cheaper and warranty repair quicker and easier for the dealer, all translating to more profit of course, yet screws over the owner in the long run. And that was 20+ years ago, I can't imagine what today's offerings will be like down the road in second and thirds owner's hands. In any event, a solution for new fittings is what I'm after and different seals don't really excite me.

 

Sorry. Looks like your connectors are way beyond repairable. Good luck.

 

No worries, that pic was for reference only. They were binned long ago. My point was that a solution is for the connectors and not simply the o-rings would add real value.

 

Used to be able to find brass Swagelok connectors that could be used but I don't believe anyones found brass just stainless steel of late. I replaced all 4 on one of my discos with the swagelok fitting and they don't drip at all and can't really fail.

edit: what you're looking for but it's not available anymore from a quick search

 

I remember your thread and searched in earnest for the Swagelok fittings you found however they are NLA at the moment. Even Swagelok doesn't list them any longer, and IIRC you can't purchase from them directly anyway.

Edit: And by the way, the factory o-rings mic out at 1.86mm in all directions. I'm guessing that being compressed made those appear to be oval, but perhaps they weren't the correct ones and were part of the reason they were leaking in the first place. Leaking from the compression fitting itself is a different problem however and luckily not one I've personally come up against. I've never had a problem with the factory version.

 

Try searching swagelok website: https://products.swagelok.com/en/c/s...2Type:Male+NPT
You can purchase most of the fittings right there