WTF-J

Day #1 on testing the cooling system I learned that the the PCM outputs a "ground trigger" (-12v) for the fan while I had wired the relay to "look" for a positive signal. (+12v)   Oops!  Not a big deal, as the relays and circuit breakers are tucked away behind the headlights in the radiator shell and it’s easy to fix.  (The red Lego-like "bricks" are actually covers over the circuit breakers.)  Once the polarity of the circuit is changed, running the WTF-J up to temp should produce the desired result and we’ll get to see whether the fan actually works.    

Day #2 was warm and sunny day and perfect for the test.  The WTF-J was full of its vital fluids and the day also provided a perfect opportunity to clean the garage floor that had become a collection of hazardous waste from filling the differentials, power steering, oil, transmission fluid, and coolant.  

The worst spillage was due to a challenging power steering leak resulting from a defective O-Ring seal at the pump.  Pulling the fitting dumped about a pint of (awful smelling) P/S fluid and replacing it was no picnic either, since the only access was from underneath where there was no escape from the effects.  The leaking fluid also made it tough to get a grip on wrenches and the stuff would run down your arm into your shirt and drip into your hair.  Eventually it all goes back together, but the floor was pretty disgusting, so it was time for a shower and power washing the work area.

Let the testing begin!  The day before, the engine temp climbed to well over 220° and stayed there; now it spikes at 190°, the fan turns on, the temp drops to ~170°, and the fan cycles off.  The P/S leak may have succumbed to the new O-Ring, but got the last laugh as a mildly overfilled the reservoir blew out the plastic bellows vent ($4 part) that sits on the top.  

The garage was looking good and the floor had dried from the pressure wash so it was time to put the WTF-J up for the night.  Made it to within 4′ from the parking spot when a loud "Pfhhhht" emanated from underneath the car and then smoke filled the garage. 

The WTF-J was doing its best Exxon Valdez imitation; a red (transmission fluid) oil spill had erupted under under the car and more of it was dripping off the frame and headers.  What a mess!  The smoke was coming from the fluid that had sprayed on the headers and the exhaust pipe.  There was also a mini flash fire that melted one of the suspension air lines that produced the "Pfhhhht" noise.   

Turns out that the culprit was a temporary transmission cooling line that popped off about 20-sec. before the engine was due to be shut off.  The temporary line was actually nothing more than a 6-8" section of hose that was slipped over the barbed fittings on the inlet/outlet of the transmission cooling lines and had been installed on a cold day so it was pretty stiff.  (The lesson learned was that the warmer weather and the hot transmission fluid significantly softened, i.e. loosened the hose.) 

The above picture shows the freshly replaced hose and you can’t help but notice rosy glow and shiny surfaces.  This time, the hoses went on completely and there are now hose clamps preventing Valdez Redux.  The irony was that right after cleaning the floor the first time, I updated the "To-Do" list on the whiteboard: Item #3 was "Install Trans Cooling Lines"

After spreading enough Oil Dry (Kitty Litter!) to blot up the mess, it was time for some Budweiser Therapy.  Getting some perspective helped and it was still early enough to refill the trans. (It took 3 qts. to get the dipstick back to full!) and back the WTF-J out (with the newly installed line!)  to re-wash the garage floor. 

The next day, it was a pretty smokey 10-20 minutes of run time as the remaining trans fluid burned off the headers and exhaust tubing, but all’s well that ends well.  Fortunately no animals were harmed in the filming of this episode.