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Cooler Bypass Valve: Installation

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.
    CAUTION: Failure to correctly install the new rubber-coated sealing washers will result in transmission fluid leaks.
    Fig 1: Installing One Rubber-Coated Sealing Washer On Each Cooler Line Case Fitting
    G02762128Courtesy of FORD MOTOR CO.
  1. 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.
    2. 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 CBV Onto Transmission Case
    G02762129Courtesy of FORD MOTOR CO.
  2. Install the CBV onto the transmission case.
  3. Install the transmission fluid cooler tube nuts.
    Fig 3: Installing Transmission Fluid Cooler Tube Nuts
    G02762130Courtesy of FORD MOTOR CO.
  4. Fill the transmission to the specified level with clean automatic transmission fluid. For additional information, refer to the Fluid Capacity chart in the GENERAL SPECIFICATIONS  portion of this article.
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