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Cooler Bypass Valve Assembly: Disassembly

WARNING: This page is about a different car, the 2004 Ford Pickup, 2004 Ford F550 Super Duty, 2004 Ford F450 Super Duty, 2004 Ford Excursion, and 2004 Ford Cab & Chassis. However, it is still accessible from the selected car via links, so may be relevant.
NOTE: The cooler bypass valve needs to be thoroughly cleaned and flushed out at this time.
  1. Remove and inspect the cooler line case fittings. If the cooler line case fittings are damaged install new cooler line case fittings.
    Fig 1: Inspecting Cooler Line Case Fittings
    G02775169Courtesy of FORD MOTOR CO.
    2. NOTE: Damaged sealing washers will cause transmission fluid to leak at the cooler bypass valve.
    Fig 2: Removing Rubber-Coated Sealing Washers
    G02775170Courtesy of FORD MOTOR CO.
  2. Remove the rubber-coated sealing washers. Inspect the sealing washers. Install new as required.
  3. Inspect the sealing ends of the cooler bypass valve. If the valve assembly is damaged Install a new coolant bypass valve assembly.
    Fig 3: Inspecting Sealing Ends Of Cooler Bypass Valve
    G02775171Courtesy of FORD MOTOR CO.
  4. 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 4: Assembling Cooler Bypass Valve And Plug
    G02775172Courtesy of FORD MOTOR CO.
  5. Place a 0.5-inch flatwasher over the case converter-out fitting threads over the rubber coated sealing washer.
    Fig 5: Placing Flatwasher Over Case Converter-Out Fitting Threads Over Rubber Coated Sealing Washer
    G02775173Courtesy of FORD MOTOR CO.
  6. Connect the cleaner pressure line to the case converter-out fitting.
    Fig 6: Connecting Cleaner Pressure Line-Case Converter-Out Fitting
    G02775174Courtesy of FORD MOTOR CO.
    7. CAUTION: Make sure the CBV is in the solvent tank before switching on the solvent pump. Also make sure the CBV fitting is pointing downward so the solvent does not spray up out of the tank.
    Fig 7: Placing CBV Into Solvent Tank
    G02775175Courtesy of FORD MOTOR CO.
  7. Place the CBV into the solvent tank.
    8. CAUTION: The solvent pressure must be at least 344.75 kPa (50 psi) (minimum) to overcome the valve inside the CBV and let the solvent pass through it. Do not, however, exceed 620.55 kPa (90 psi) (maximum) solvent pressure.
    Fig 8: Identifying Regulate The Solvent Pressure
    G02775176Courtesy of FORD MOTOR CO.
  8. Regulate the solvent pressure as specified. Switch on the solvent pump allowing the solvent to circulate through the CBV for 5 minutes. During this time, cycle the solvent pump on and off to help dislodge contaminants.
  9. Disconnect the cleaner pressure line from the case converter-out fitting. Remove the 0.5-inch washer.
    Fig 9: Disconnecting Cleaner Pressure Line From Case Converter-Out Fitting
    G02775177Courtesy of FORD MOTOR CO.
  10. Using 344.75-620.55 kPa (50-90 psi) of regulated compressed air, blow through the CBV until all solvent is removed.
  11. Remove the plug from the CBV converter-out-to-cooler inlet.
    Fig 10: Removing Plug From CBV Converter-Out-To-Cooler Inlet
    G02775178Courtesy of FORD MOTOR CO.
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