Cooler Bypass Valve: Installation

WARNING: This page is about a different car, the 2002 Ford RV Cutaway, 2002 Ford Econoline, 2002 Ford E550 Super Duty, 2002 Ford E450 Super Duty, and 2002 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.

Install new rubber-coated sealing washers and new cooler line case fittings.
1. Install one rubber-coated sealing washer on each cooler line case fitting.
2. Install both cooler line case fitting into their respective ends of the CBV assembly.
3. Install one rubber-coated sealing washer on each cooler line case fitting.
  
  Fig 1: Installing New Rubber-Coated Sealing Washers And New Cooler Line Case Fittings
  Courtesy of FORD MOTOR CO.

CAUTION: Make sure the cooler bypass valve (CBV) is correctly backflushed. Use dry compressed air to remove solvent.

CAUTION: If the cooler line case fitting is over-tightened the rubber coated sealing washers and/or cooler line case fittings can be damaged, causing a transmission fluid leak.

NOTE: The CBV has a check ball in the rear fitting and will only allow flow in one direction. Make sure check ball moves freely.

NOTE: Align the two rubber coated sealing washers, while assembling the rear CBV fitting.

Fig 2: Installing Cooler Line Case Fitting

Courtesy of FORD MOTOR CO.

Install the cooler line case fitting.
Tighten the cooler tube nuts.

Fig 3: Identifying Cooler Tube Nuts For Tightening
Courtesy of FORD MOTOR CO.
Lower the vehicle.
Fill the transmission to the specified level with clean automatic transmission fluid. For additional information, refer to the Fluid Capacity .