Okay...I've been through all 317 pages of threads in this forum and I didn't see what I was looking fer. <img src="/forums/images/graemlins/frown.gif" alt="" /> <img src="/forums/images/graemlins/confused.gif" alt="" />

Yes, I've looked through the Internet and some of the other forums and haven't found what I would like to know. As far as I can tell...no one has done anything like this.

So I guess I'll start here first! This is my first thread here...so be gentle! <img src="/forums/images/graemlins/wink.gif" alt="" />

I've seen the various temp monitoring gauges fer water, tranmission, oil, and brake temps. Nice...but I've noticed one thing about them. The only thing they do is just monitor temps. <img src="/forums/images/graemlins/frown.gif" alt="" /> Some users report that the gauges don't seem like they are even working.

So I ask...why isn't there a temp control system that allow outputs fer active cooling/notification? Something just like yer house thermostat. Not only will it tell you the temp but when the sensor reaches a certain temp, turn on a cooling fan or/and an alarm/flashing light. Kind of like set it and fergit about it!

I'm not sure what most of you do if you git overheating in yer tranny or brakes...I'm thinking that you would pull over and let those parts cool down and let time take it's course. I was thinking of hooking up a blower or fan to the controller and when the temps hit a particular high temp, the blowers come on to cool that item or yer auxillary cooling unit. When it drops to a certain temp, you can have it turn off the blowers automatically.

I've noticed that Raylin offers a brake temp montoring system from $190 to $240. But that's all it does...just tell you the temp.

The same goes fer the tranny analog temp gauges. <img src="/forums/images/graemlins/frown.gif" alt="" />

I know that most of you like the analog gauges but I haven't found any that will allow an output... <img src="/forums/images/graemlins/frown.gif" alt="" />

So I've decided to kinda put one together of my own. <img src="/forums/images/graemlins/wink.gif" alt="" /> Not sure exactly where I could mount it...I guess I'll could make a custom mount and put it up on the left corner of the dash. That would make it eye level fer easy reading and not too obtrusive. I guess some of you could even put it in the left courtesy pocket below the left vent and run the cabling out the back of that pocket. <img src="/forums/images/graemlins/wink.gif" alt="" /> That might make it kinda hard to read but I don't think it would need to be monitored all the time... <img src="/forums/images/graemlins/smile.gif" alt="" /> I guess you could even put in an manual over-ride switch fer the fan/blower.

I've found some digital temp switches made by Dwyer Instruments that run off of 12VDC. They have a few models that would work and aren't too obtrusive. The only thing is about these is that I don't know how quickly they respond to temp readings or how often it reads the sensor. They seem to be accurate within 1?F.

First there's the TCS series.
Models TCS-4030 (?F) and TCS-4031 (?C) are the 12V models. The range that they measure is from 0 to 999?F. Dimensions are 3" wide, 2.375" deep, and 1.338" tall (faceplate)/1.1" tall body. Install hole needs to be 2.80" x 1.14". Display is a 3-Digit, Red, 1/2ö (12.7 mm) digits, plus sign. It will accept a type J or K input. Price on either module is about $50 and doesn't come with any sensor probes.

Second, there's the TS2 series.
Models TS2-030 (?F) and TS2-031 (?C) are the 12V models. The range that they measure is from -50 to 302?F. Dimensions and prices are the same as the TCS series.

Third, there's the TS series.
Models TS-13030 (?F) and TS-13031 (?C) are the 12V models. The range that they measure is from -50 to 302?F. Dimensions are the same as the TCS series. Price on either module is about $54 and doesn't come with any sensor probes.

Fourth, there's the TSS, TSR, and TST series. These models have dual input and multiple outputs (relay and alarm) The TSS and TSR (TSR-0110/TSR-1110) have dual relay outs, TST (TST-0110/TST-1110) has triple relay outs. The range that they measure is from -50 to 302?F. Prices are TSS ($85), TSR ($89), and TST ($109).

All of these have nonvolatile memory backup...that is, you can set it up to power up with yer truck and not have to redo all of yer settings. They also have temp offset adjustments as well as user preset settings. There's even an indicator when the relays are active. These all have the makings of reporting and actively controlling temps.

The key to this system will be the sensor probes. I see that Autometer makes a cylinder head temp sensor that mounts under the spark plug which might work fer monitoring the brake temp. Not too bad fer about $76 or so... I'm not sure if the tranny sensors currently out there will work with this digital switch. A few of my chatroom buddies have mentioned an IR sensor instead of the contact sensor. Not sure what's out there and if it will work directly with the switch. Maybe with another module or something... <img src="/forums/images/graemlins/wink.gif" alt="" /> I'm sure the price of the IR modules/sensors will probably put this project out of reach fer too many people. <img src="/forums/images/graemlins/frown.gif" alt="" />

So what do y'all think of this type of system? This is gonna take me awhile to figure out since I don't do towing or heavy loads...at the moment. You could think of this like a safety item...it's there when you need it most! <img src="/forums/images/graemlins/smile.gif" alt="" />

I figure I'd do this in 2 stages...start out with just a monitoring system first and then add the blowers later. <img src="/forums/images/graemlins/wink.gif" alt="" />

Found a washer contact sensor fer $21!

Sounds like a lot of work to me. I wish I had that much time on my hands to even think about this subject. There are a few mods you could do, that would keep these components from over heating, under most all circumstances. Just remember, It's just a truck. Not a rocket science project. Anyway, good luck! Hope you find what you are looking for.

Well...someone has to do the work... <img src="/forums/images/graemlins/wink.gif" alt="" />

Just bought the $50 TCS-4030 temp switch and the $21 washer contact sensor ($26 shipped). So I'm in fer about $85 with shipping. I'll take piccies of the items and how well it works together. <img src="/forums/images/graemlins/smile.gif" alt="" />

I'll probably end up testing the unit on the brakes first (not exactly sure where on the caliper I can put them) and then the tranny and see how close they git by comparing them with an infrared temp gauge.

The first test will be to hook up the sensor to the unit and then 12VDC power. Then some quick water temp tests and how quickly the sensor reacts from ambient to hot and then cold water. <img src="/forums/images/graemlins/wink.gif" alt="" />

Using industrial process controls is going to make it needlessly expensive. Much easier would be to use plain old thermistors, and roll your own control and interface with a small embedded controller. See the 8051 cores from Atmel and Maxim/Dallas! There are controllers with ADC's onboard, and if you need more, use a controller with onboard I2C instead, and put all your input and output peripherals on I2C. Use a transistor and relay for switching.

For probes there are already lots of good sensors that come as parts of cars already. Transmission and axle temp sensors can go into the drain plugs. It's difficult to get accurate engine oil temp. I would prefer to have this at the oil pump, and the probe must be in the flow, this is usually hard but we have oil coolers with hoses.

So what to do about active cooling? Sure if you have an automatic transmission an electric fan in front of the radiator will help. With everything else, you can't do much about it. People usually replace their axle housings for ones which hold more oil and have big cooling fins, if they get warm.

I think you can feel it when your brakes get too hot. Also it might not be the temperature of your brake rotors that is causing the malfunction, but of the brake fluid.

We are getting off topic for the board!

I think eleet is right. This sounds like a lot of time and money to find out the factory and after market stuff is adequate for nearly every need. Industrial plc probes can do lots for you and some of them are relatively cheap. But you need a plc. IR sensors for the brakes would work, you would have to mount them to something cushioned as most cannot take the pounding of a moving suspension. In flow sensors can be done as well - tranny cooler and oil coolers externally mounted. But back to my initial statement - get tranny coolers and oil coolers that have the biggest cores possible for max cooling if that is what you need. Bolt on a thermistor controlled fan if you want. Brake rotors with cross drillings and good design vents do wonders. You can also add ducting to pass more air over them. Or follow NASCAR and actually have a fan blow even more on them - although with those guys, if you can't get enough air moving over your brakes at 180 mph, well.......

Bottom line, you can get all the cooling you want with after market stuff. If the geek in you wants readouts, then you will have to spend real money. Personally, I do not see the benefit of knowing oil temps are 100F below breakdown point for a non race car....And for brakes, the pads and rotors are not usually the problem with brake fade when hot. The fluid is boiling. Use high end racer's fluid and you will get a big surprise in that category.

Only thing i found needfult was a Transmission temp. guage, gives me an opportunity to monitor temps and know when its getting hot before the light comes on and its cooking...

In addition to the temp guage i installed a flex-a-lite 295 fan, problems with the fan controller are common, but i installed a manual on switch, i keep the fan on full time offroad to pull the air through my aux. transmission cooler.

I had a 92 Dodge Cummins Diesel PU and there was a factory tranny cooler I installed on that since the Cummins put out way more power then the tranny could take and it would overheat. It was frame mounted with a fan that came on at a preset temp. The noise from the fan let you know you were hot and it worked well. There might still be some out there you could pick up cheap and adapt.

Thanks fer the input!

I'm just trying to go in an area that doesn't look like it's been traveled at all...at least fer everyday driving.

Not too sure if people are willing to build their own controller and trust in it's accuracy. It took me about 2 weeks to hunt down something that was already built fer 12V, durable, and warrantied.

I know this is a 4x4 forum and probably most of you don't even tow things with yer 4x4 rigs to worry about tranny or brake temps. But of all the other forums, this seems to have the most traffic. I know my 1993 T-100 2WD won't do any serious towing or even probably heat up the brakes from towing but I thought I'd give it a shot here to git some feedback on the idea/concept/build.

I know the key on the brakes is the fluid breaking down from the heat transfer from the pads. But besides the Raylin device, there isn't any other options fer brake temp monitoring as well as active cooling. How many of you that do towing have overheated yer brakes? It might be a few if any of you that might fall into this category but I'm sure you would've appreciated an option fer cooling yer brakes instead of sitting on the side of the road or even in a garage.

Kinda like airbags...people didn't think too much of them in the beginning and it had it's faults, difficulties, and costs. Now it's pretty much a standard in any vehicle you buy today. <img src="/forums/images/graemlins/wink.gif" alt="" /> How many of you have pulled/disabled yer airbag in yer rigs? <img src="/forums/images/graemlins/smile.gif" alt="" /> My T-100 doesn't have one so I don't worry about it...

I've contacted the local Toyota dealership and they told me that there aren't any temp sensors that he could find me fer my truck. So that's why I've looked at other sources and ideas.

Well...just found out the switch is on it's way but...the sensor is back ordered fer 2 weeks. Dang... <img src="/forums/images/graemlins/frown.gif" alt="" />

Guess I'll have to see what other sensors I can use then... <img src="/forums/images/graemlins/smile.gif" alt="" />

Found a universal transmission temp sender from DakotaDigital fer only $10.25 plus $8.07 shipping ($18.32 total). Not too bad.

How about an extra washer bottle and pump? Spray water on the brakes. If they're really hot, then they won't really be wet won't they?

I could put that into the temp switch and use an extra fine mister but instead of aiming at the rotors...I think I would point the mister at the calipers because the key here would be to keep the fluid as cool as possible. Thanks fer the idea!

I know if you put too much water on heated metal it could warp/heat fracture it...hence the extra fine mister.

I guess I could still build this out with a blower pointed to the air intake of the rotors and an extra fine mister fer the calipers with a low water sensor fer the water bottle. Let's see...a gallon of water weighs about 8lbs... <img src="/forums/images/graemlins/wink.gif" alt="" />

I noticed on the calipers that there is a vent hole that allows the rotor air to kinda cool the calipers. I'm thinking of putting my sensor on that...just have to use a carriage bolt that I would thread from the inside and lock it down with a nut. Use a second nut to attach the sensor to and also lock the first nut from spinning out. <img src="/forums/images/graemlins/smile.gif" alt="" />

I want to remind people that when this device is used fer braking, it would only be used in a brake overheating potential emergency (in almost all cases...going downhill and carrying/towing a load). I don't see this setup being used as an everyday event (unless you really like yer brakes running cool and you stomp on them a lot) as the upper temp limit that you set would be the triggering event (most likely near the brake fade temp of just over 200?F).

As far as a transmission temp control device, this would sort of be a combination of what's already out there but with more user control. This setup with an auxiliary cooler and a blower could give you feedback temps AND would be able to control yer blower/fan at the same time.