Flex-a-Lite 4116XJ User Manual

COOLER KIT ­Jeep Cherokee XJ 1987 - 2001

Part #4116XJ Recommended - Rad. / Fan Kit #67108

& Rad. only Kit #67100 for replacement

“Auxiliary transmission cooler” - Automatic Transmission Only

Note: Always read instructions and verify kit contents prior to installation.

Cooler ........................................ 1 ea.

Brackets, Cooler Mounting ........ 2 ea.

Channel ..................................... 2 ea.

Rubber Hose @ 4ft .................... 2ea.

Instruction Sheet ....................... 1 ea.

Flex-a-lite Decal ......................... 1 ea.

*Hardware Kit ............................ 1 ea.

* Hardware Kit Includes:

bolt hex head 1/4-20 x 1-1/2” ...... (4ea)

nut nylock 1/4-20 ........................ (4ea)

gatorclip 1/2” ...............................(8ea)

worm drive hose clamp ............... (4ea)

nylon tie straps ........................... (4ea)

plastic spacer .............................. (4ea)

screw PH 1/4-20 x 1/2” ............... (4ea)

INSTALLATION INSTRUCTIONS

Note: Special Tools Required: “tubing cutter” & “flaring tool”

Note: To view these instructions, visit www.flex-a-lite.com or call 1-877-767-0554

or FAX: [phone] for Technical Assistance. It is HIGHLY recommended to read and

review these instructions prior to installation.

BE SURE THE ENGINE IS OFF AND COOL BEFORE PROCEEDING!

Start installation by laying out all contents of kit and compare to parts list above.1.

Disconnect transmission lines from radiator. Cap the ends of the metal transmission cooling lines to prevent 2.
line leakage. Be mindful of possible leakage from fittings of radiator during removal of radiator from vehicle.

Remove existing cooler (if applicable): 3.
Because the existing cooler is designed to run through the radiator tank for additional cooling, there is no
longer a place to connect the transmission cooler lines. The replacement Flex-a-lite cooler 4118XJ is a
higher capacity direct fit transmission cooler that will better meet your transmissions’ cooling needs and
improve its life expectancy.

Grill removal: 4.
Remove the headlight beauty rings and then the front grill. Removal of the grill allows you to position the
cooler with connected brackets and make adjustments as necessary.

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Installation instructions continued from previous page

Removal of top radiator support: 5.
The installation of the cooler requires that you sandwich the
cooler’s bent mounting brackets between the long radiator support
and long “L-bracket”. Remove the Torx bolts securing center hood
latch bar on top of radiator support. Remove the Torx bolts and
10MM nuts securing the long “L-bracket” along top of radiator
support (see Detail A-1). Remove 10 MM nuts 2ea. releasing
rubber mounts below radiator support along top of radiator (see
Detail A-2). Along top of radiator remove 10 MM bolts securing
radiator support at right and left sides of support (see Detail A-3).
Lift and remove the long radiator support.

Assemble the cooler / bracket assembly: 6.
Per the “exploded assembly view” shown below. It is suggested
that assembly of the cooler / brackets be made using the hole and
slot locations shown. Vehicle equipment variations may require
shifting placement of the cooler along channels.

Radiator Support, long

“A-1” “A-2”“A-3”

Detail A

Mounting Bracket

(2ea)

“Cooler / Bracket Exploded Assembly”

Nut - nylock

1/4-20 (4ea)

Extruded channel

(2ea)

Gator clip

(8ea)

Transmission

Cooler

(1ea)

Screw - 1/4-20 x 1/2

(4ea)

Plastic Spacer

(4ea)

Bolt - hex HD

1/4-20 x 1-1/2” (4ea)

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