Problem with trans cooler pipe replacement

[Lola598]

2002 Sierra 2500 HD Crew Cab Short Bed w/8.1 L
Last 8 of VIN 2F136357

I've had to replace the transmission cooler and the two pipes that connect to it because of leaks. Figured it would be fairly straight forward but needless to say not so.

First problem was the trans end pipe adapter called out on the drawing and parts list was incorrect. Is 88996640, should be 29540501. After a fair number of back and forths with parts guys got this sorted out.

Second problem, and I'm really worried that this could be a real show stopper, is the replacement pipe that runs from the cooler to the transmission has been made to a different spec. than the original. The bend radius for the 90 degree bend closest to the transmission adapter is approximately 1/2" larger on the replacement than on the original. The fallout of this is that pipe is 1/2" further away from the transmission and cannot be installed without moving the exhaust pipe and even at that will hit the exhaust pipe when in service. The other issue is that by increasing the bend raduis 1/2" the pipe is now shorter by 1/2" and does not line up with port opening on the transmission.

Has anyone run into this and if so is there a solution?

Thanks

I would have attached photos but they are 20K bigger than the forum limit.

 

[happy 2011]

sounds like the line is diffent at the trans end and the bend is not correct?

What i would do is buy a tubing bender (unless u have 1) starighten the line out with a vice (carefully) then rebend the line like the old one.

That is if i'm reading your post right good luck

 

[Lola598]

You're correct about the bend.

If I have to kluge something together I am more inclined to cut a section out and replace it with hose and clamps giving me the ability to rotate the pipe at the transmission to clear the exhaust pipe. I would be afraid that I might crack the pipe if I try to straighten and rebend.

What I would really like is for GM to tell me why it doesn't fit. Did the pipe spec get changed without taking into account this application? Did the pipe get fabricated incorrectly? Or, and I am hoping this is the case, is this the wrong part number, as was the case in the quick release adapter.

I discovered just yesterday that the pipe part number changed from '02 to '03. I have not yet seen an '03 but maybe my truck was made late in '02 with an '03 spec. Most likely wishful thinking.

If anyone is interested I can forward a photo.

 

[happy 2011]

then i would take the old line and new line to the dealer. Ask for the parts manger to make the problem go away. (get the correct line)

But i also rebend trans lines and oil cooler lines all the time by doing what i said above.

 

[Lola598]

then i would take the old line and new line to the dealer. Ask for the parts manger to make the problem go away. (get the correct line)

But i also rebend trans lines and oil cooler lines all the time by doing what i said above.

I asked the parts manager to make the problem go away and he can't. It would seem that GMC dropped the ball on this one as the correct part does not exist.

His technician looked at the photos I sent in and suggested that removing and then replacing the exhaust pipe would allow me to install the pipe, unfortunately the exhaust would there would still be an inteference.

So I think I might be able to bend the 90 degree to 100 or 105 and then put a 10 or 15 degree at the point of interference and S bend the pipe around the exhaust.

I have a Sears brake line bender but max dia is 3/8. Do you know of a similar hand held that will bend 5/8?

It would be really interesting to see the manufacturing drawing with the rev history for this pipe.