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Thread: Internal diameter of disco 2 transmission hoses

  1. #1
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    Internal diameter of disco 2 transmission hoses

    I'm in the process of getting a separate trans cooler installed for my trust 2000 disco that I've had since 2008 and it's a cause of some annoyance!

    Before I dribble on a bit, I need to know the internal diameter of the transmission lines? The fixed metal and flexible...are they 3/8 or 5/16? I read on another post they possibly could be 1/2 but I couldn't be quite sure.

    I do a lot of work myself but not keen on this, I consider it a bit of a pest and I want it done right. Replacing it to keep my ? original ZF-4HP-22 in the best of nick, I have a performance IC for a "manual" to install (so factory trans cooler needs to go), and I weary the original swathe style fittings for the flex hoses are a potential weakness and I'm keen to do some work to prevent them letting go after ~22yrs.

    I did get a second hand P38 cooler in good nick but I'm far (100+km) from decent hydraulic place (enzed, pirtek) and no one local wants to do the work with my secondhand cooler. Not a waste. Only $100 and I can re-sell it or just keep it spare.

    So I've gone to a place I trust, but they've asked me to supply own cooler and provided a place in Melb. Rang them up and they said they can supply a custom kit but need to know the ID of the transmission lines. Argh.

    I've also gotta make sure what fittings they are supplying to connect to the hard lines etc. And that their cooler can survive the suspected 150-200PSI from the ZF.

    Thanks in advance.

  2. #2
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    1/2". I bought the biggest PWR 1/2inch barb model they had, mounted it as close to the grill, far away from the other rads and ran this 80deg thermo in line,
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  3. #3
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    All measurements rounded up, and I didn't measure in imperial(I'm a hard core metric type! )

    The hose is:

    OD: 19.8mm . ID: 13.8mm . Wall thickness of hose I measured at 3mm

    The pipe at the quick connect fitting is
    Pipe itself is OD 12.8mm
    ID on the quick connect pipe is 10.7(but I measured the the pipe thickness here at 0.9mm)
    The bead on the pipe is 14mm.

    Whilst not a huge difference, the main pipe(from flexi to threaded nut) I measured at 12.9mm.
    It's only 0.1mm difference in size compared to the quick connect pipe section ... could have been just measurement error or more dirt/rust/scale on the main pipe sections or whatever.
    Couldn't measure the ID of the main pipe tho.

    What I'm contemplating with my (now) spare pipes, is to braze a threaded end onto them to remove the compression fittings for the flexi hose. Then remove quick connect ends and fit same thread there, and just use easily available AN fittings of appropriate size.

    On my(not really mine, but I just call it that now!) D2 the compression fitting at the quick connect popped. Of all the stupid sections to let go! You would have thought being a compression fitting, it'd be the more durable section .. and maybe the hose would have split first .. or something(or even the quick connect fitting itself would have weakened before the permanent fitted section.

    The new pipes came it at just over $400 together, only needed the passenger side one, but better peace of mind to have both done now .. which normally would be ok, say if a pipe was damaged, or rusted, or whatever ...
    But to renew the entire assembly because of a simple cheap section of it failed .. annoying.

    A better design would have been to have threaded ends on the main section of pipe(from trans) .. and a threaded fitting on the flexi hose .. this way if the hose breaks you wouldn't have needed to remove the main section of pipe(ie. just the hose) .. could have been cheaper, but more importantly easier fitment. The top pipe is a major PITP ... (P = Posterior ) to remove and refit.
    Arthur.

    '99 D1 300Tdi Auto
    '03 D2 Td5 Auto

  4. #4
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    Thanks.

    Yeah, the compression fittings make some nervous and are a ? weak point should it fail making it harder for a roadside fix.

    I can't believe how many transmission gurus are surprised when 1/2" ID is mentioned, seems like it's super not standard.

    Also shocked a fairly decent transmission joint couldn't supply a cooler with 1/2" fittings. That kinda left PWR or my second-hand P38 cooler.

    I'm gonna go back to my P38 cooler, get Enzed / Pertec to help get fittings with 1/2" barbs, some 1/2" ID hose and rejig my transmission cooling myself.

    Got a new radiator and a Allisport full-sized IC to go in at the same time to replace the ~22yr originals.

  5. #5
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    Internal diameter of disco 2 transmission hoses

    Quote Originally Posted by Disco Jase View Post
    I'm in the process of getting a separate trans cooler installed for my trust 2000 disco that I've had since 2008 and it's a cause of some annoyance!

    Before I dribble on a bit, I need to know the internal diameter of the transmission lines? The fixed metal and flexible...are they 3/8 or 5/16? I read on another post they possibly could be 1/2 but I couldn't be quite sure.

    I do a lot of work myself but not keen on this, I consider it a bit of a pest and I want it done right. Replacing it to keep my ? original ZF-4HP-22 in the best of nick, I have a performance IC for a "manual" to install (so factory trans cooler needs to go), and I weary the original swathe style fittings for the flex hoses are a potential weakness and I'm keen to do some work to prevent them letting go after ~22yrs.

    I did get a second hand P38 cooler in good nick but I'm far (100+km) from decent hydraulic place (enzed, pirtek) and no one local wants to do the work with my secondhand cooler. Not a waste. Only $100 and I can re-sell it or just keep it spare.

    So I've gone to a place I trust, but they've asked me to supply own cooler and provided a place in Melb. Rang them up and they said they can supply a custom kit but need to know the ID of the transmission lines. Argh.

    I've also gotta make sure what fittings they are supplying to connect to the hard lines etc. And that their cooler can survive the suspected 150-200PSI from the ZF.

    Thanks in advance.
    I have a PWR cooler that I will be installing soon. I will be using -8 (ie dash 8) A&N fittings to connect the factory lines to the cooler via suitable spec hose - there will be no swaged fittings in the systemInternal diameter of disco 2 transmission hoses. It is a straight forward DIY job if you are that way inclined.
    LROCV member #131
    1999 build D2 TD5 Auto, Mantec snorkel, 2" LRA spring lift, ARB on board air, Ashcroft ATB, CMM air ram CDL shifter, swag & gold pans ....

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