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The cooler line connections that connect to the aw4 transmission on my 89 jeep Comanche were leaking when to change both out and as i threaded one of the line connector in to the aw4 trans in snapped the threads on the housing, my question is can just but a weld in the whole and only have one transmission cooler line or will it cause problems,

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You need both lines in order for the trans to function. One is an inlet and one is an outlet. You may be able to weld that broken piece back on IF it is in one piece but that would be extremely hard to make work and likely wouldn't last. Your best bet is to hit the JY and find a used aw4 from an XJ and swap it in. They can be found cheap and are everywhere.

 

To make the install easier, look for a similar year to your truck. Any aw4 will work (in 98 they added a second speed sensor. You could use one of these as well but just leave the input speed sensor as a dummy plug). You will probably need to swap sensors from your current trans to the new one everywhere else tho.

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Ouch that makes it hard for a good repair.

 

not everyone would agree with me, however I would do this.

 

grind down the rest so flat. then I would adapter with 1 to 2 size bigger thread fitting. tap it out to the much larger size. Then put the new adapter in the trans, make sure it seals by using some locker. Maybe even a few drops of on the tread to make it permanent. Then you can adapt your cooler line to the new fitting on the trans.

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Yeah, well, few people ever agree with me, either. 

 

 

There are VERY few things that JB Weld is good for, this is one of them. 

 

You still have some thread left from what I can see.

 

Clean it up, maybe even stuff a bit of rag in the hole that you can remove with tweezers, use a Dremel, denatured alcohol, whatever it takes. 

 

JB the threads and the mating surface, thread it back in gently, let it set up over night. 

 

 

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If you found the fitting type that the connection goes into, and then that in female, with a pipe thread on the other end. Then tap the broken area for that pipe thread. So it should be a threaded O-ring port with a pipe thread on the male end.

 

Edit: so Female Straight Thread O-ring fitting (measure size of present thread) to a Pipe Thread (that would near fit inside the present hole. Also, put grease on the tap to hold the chips to it. So, they don't get inside the trans.  I had a model airplane engine head done this way for its muffler. Think I've seen it done elsewhere.

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