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Cooler Bypass Valve - 4R100 Transmission: Installation

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.
    CAUTION: Failure to correctly install the new rubber-coated sealing washers will result in transmission fluid leaks.
    Fig 1: Installing Rubber-Coated Sealing Washers And Cooler Line Case Fittings
    G01540088Courtesy of FORD MOTOR CO.
  1. Install the new rubber-coated sealing washers and the new cooler line case fittings
    1. Install one rubber-coated sealing washer on each cooler line case fitting.
    2. Install both cooler line case fittings into their respective ends of the CBV assembly.
    3. Install one rubber-coated sealing washer on each cooler line case fitting.
    2. CAUTION: Damage will occur to the rubber-coated sealing washers and transmission fluid will leak if the cooler line case fittings are overtightened.
    NOTE: Align the rubber-coated sealing washers while installing CBV assembly on the transmission case.
    Fig 2: Installing CBV Assembly
    G01540089Courtesy of FORD MOTOR CO.
  2. Install the CBV assembly.
  3. Install the fluid cooler tube in the front cooler bypass valve assembly fitting and in the rear cooler line case fitting.
    Fig 3: Installing Fluid Cooler Tube In Front Cooler Bypass Valve Assembly Fitting
    G01540090Courtesy of FORD MOTOR CO.
    4. 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.
    CAUTION: Failure to follow the instructions supplied with the inline transmission fluid filter kit can cause transmission damage.
    CAUTION: Verify that the flow arrow on the filter points toward the transmission.
    Fig 4: Installing Inline Transmission Fluid Filter
    G01540091Courtesy of FORD MOTOR CO.
  4. Install a new inline transmission fluid filter (XC3Z-7B155-BA). 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. Carry out the transmission fluid cooler flow test procedure to verify that there is correct fluid flow through the new inline fluid filter. For additional information, refer to AUTOMATIC TRANSAXLE/TRANSMISSION-4R100 .
  5. Lower the vehicle.
    6. CAUTION: Do not use any fluid approved for MERCON V application. Using a fluid rated for MERCON V may cause internal damage in MERCON only applications.
  6. Fill the transmission with the specified type and quantity of transmission fluid. For additional information, refer to AUTOMATIC TRANSAXLE/TRANSMISSION-4R100 .
    • Use Motorcraft MERCON Multi-Purpose (ATF) Transmission Fluid XT-2-QDX or equivalent meeting MERCON specifications.
  7. Check for leaks.
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