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Cooler Bypass Valve Assembly: Disassembly

WARNING: This page is about a different car, the 2004 Ford Econoline, 2004 Ford E450 Super Duty, and 2004 Ford Cutaway. However, it is still accessible from the selected car via links, so may be relevant.
NOTE: The cooler bypass valve (CBV) needs to be thoroughly cleaned and flushed out at this time.
NOTE: Inspect the cooler line case fittings and the sealing washers. If the cooler line case fittings or sealing washers are damaged install new cooler line case fittings and washers.
NOTE: Damaged sealing washers will cause transmission fluid to leak at the cooler bypass valve case fittings.
  1. Disassemble the CBV.
    1. Remove and discard the sealing washers.
    2. Remove the CBV case fittings.
    3. Remove and discard the sealing washers from the CBV case fittings.
    Fig 1: Removing And Discard Sealing Washers From CBV Case Fittings
    G02762284Courtesy of FORD MOTOR CO.
  2. Inspect the sealing ends of the CBV. If damage is indicated, install a new CBV.
    Fig 2: Inspecting Sealing Ends Of CBV
    G02762285Courtesy of FORD MOTOR CO.
  3. Assemble the cooler bypass valve and plug the converter-out-to-cooler inlet with a 13 x 1.5 mm (0.06 in) plug.
    Fig 3: Assembling Cooler Bypass Valve And Plug Converter-Out-To-Cooler
    G02762286Courtesy of FORD MOTOR CO.
  4. Place a 0.5-inch flatwasher over the case converter-out fitting threads over the rubber coated sealing washer.
    Fig 4: Placing Flatwasher Over Case Converter-Out Fitting Threads
    G02762287Courtesy of FORD MOTOR CO.
  5. Connect the cleaner pressure line to the case converter-out fitting.
    Fig 5: Connecting Cleaner Pressure Line To Case Converter-Out Fitting
    G02762288Courtesy of FORD MOTOR CO.
    6. CAUTION: Make sure the CBV is in the tank before switching on the pump. Also make sure the CBV fitting is pointing downward so the fluid does not spray up out of the tank.
    Fig 6: Placing CBV Into Tank
    G02762289Courtesy of FORD MOTOR CO.
  6. Place the CBV into the tank.
    7. CAUTION: The pressure must be at least 344.75 kPa (50 psi) (minimum) to overcome the valve inside the CBV and let the fluid pass through it. Do not, however, exceed 620.55 kPa (90 psi) (maximum) pressure.
    Fig 7: Identifying Switch On Pump Allowing Fluid To Circulate Through The CBV
    G02762290Courtesy of FORD MOTOR CO.
  7. Regulate the pressure as specified. Switch on the pump allowing the fluid to circulate through the CBV for 5 minutes. During this time, cycle the pump on and off to help dislodge contaminants.
  8. Disconnect the cleaner pressure line from the case converter-out fitting. Remove the 0.5-inch washer.
    Fig 8: Disconnecting Cleaner Pressure Line From Case Converter-Out Fitting
    G02762291Courtesy of FORD MOTOR CO.
  9. Using 344.75-620.55 kPa (50-90 psi) of regulated compressed air, blow through the CBV until all the fluid is removed.
    Fig 9: Identifying Regulated Compressed Air Blow Through CBV Until All Fluid
    G02762292Courtesy of FORD MOTOR CO.
  10. Remove the plug from the CBV converter-out-to-cooler inlet.
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