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Cooler Bypass Valve - 4R100 Transmission: Removal

WARNING: This page is about a different car, the 2003 Ford RV Cutaway, 2003 Ford Econoline, 2003 Ford E550 Super Duty, 2003 Ford E450 Super Duty, and 2003 Ford Cutaway. However, it is still accessible from the selected car via links, so may be relevant.
  1. Raise and support the vehicle.
    2. CAUTION: Install a new inline transmission fluid filter (XC3Z-7B155-BA) every 48,000 km (30,000 miles) and always as part of a transmission overhaul or exchange. If the vehicle was not equipped with an inline fluid filter install a new inline transmission fluid filter kit (XC3Z-7B155-AA) according to the instructions supplied with the kit as part of a transmission overhaul or exchange.
    NOTE: The inline transmission fluid filter, if so equipped, is attached to the fluid cooler return tube. The fluid cooler return tube runs from the intank transmission fluid cooler or the auxiliary transmission fluid cooler, if so equipped, to the rear transmission cooler tube case fitting.
    Fig 1: Removing And Discarding Inline Transmission Fluid Filter
    G01540083Courtesy of FORD MOTOR CO.
  2. Remove, and discard the inline transmission fluid filter, if so equipped.
  3. If not done previously, carry out the transmission fluid cooler flow test procedure. For additional information, refer to AUTOMATIC TRANSAXLE/TRANSMISSION-4R100 .
  4. Remove the fluid cooler tube from the front cooler bypass valve assembly fitting.
    Fig 2: Removing Fluid Cooler Tube From Front Cooler Bypass Valve Assembly Fitting
    G01540084Courtesy of FORD MOTOR CO.
  5. Remove the fluid cooler tube from the rear cooler line case fitting.
    Fig 3: Removing Fluid Cooler Tube From Rear Cooler Line Case Fitting
    G01540085Courtesy of FORD MOTOR CO.
    6. NOTE: The two rubber-coated sealing washers can fall out when removing the cooler line case fitting.
    Fig 4: Removing And Discarding Front Cooler Line Case Fitting
    G01540086Courtesy of FORD MOTOR CO.
  6. Remove, and discard the front cooler line case fitting and the two rubber-coated sealing washers.
    7. NOTE: The two rubber-coated sealing washers can fall out when removing the cooler line case fitting.
    Fig 5: Removing And Discarding Rear Cooler Line Case Fitting
    G01540087Courtesy of FORD MOTOR CO.
  7. Remove, and discard the rear cooler line case fitting and the two rubber-coated sealing washers.
  8. Remove the cooler bypass valve (CBV) assembly (7H322) from the transmission.
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