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Home >> Ford >> 2000 >> Contour SE, 2.5 L, Standard >> Repair and Diagnosis >> External Pages >> Different car >> Section 665 (Automatic Transmission - 4R100 - Excursion & F250-F550 Super Duty) >> In-Vehicle Repair >> Cooler Bypass Valve >> Installation

Cooler Bypass Valve: Installation

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.
    CAUTION: Failure to correctly install the new rubber-coated sealing washers will result in transmission fluid leaks.
  1. Install the new rubber-coated sealing washers and the new cooler line case fittings.
    1. Install one rubber-coated sealing washers on each cooler line case fittings.
    2. Install new cooler line case fittings into their respective ends of the CBV assembly.
    3. Install one rubber-coated sealing washers on each cooler line case fittings.
      Fig 1: Installing One Rubber-Coated Sealing Washers On Each Cooler Line Case Fittings
      G02775014Courtesy of FORD MOTOR CO.
    2. 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 overtightened, 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 cooler line case fitting.
    Fig 2: Installing CBV Fitting
    G02775015Courtesy of FORD MOTOR CO.
  2. Install the CBV fitting.
    3. CAUTION: If an overhaul is being carried out, the oil-to-air (OTA) cooler will need to be replaced.
    NOTE: The cooler lines need to be flushed out at this time and install a new OTA cooler. For additional information on installing a new OTA, refer to AUTOMATIC TRANSAXLE/TRANSMISSION EXTERNAL CONTROLS . Do not backflush the OTA cooler.
    Fig 3: Tightening Cooler Tube Nuts
    G02775016Courtesy of FORD MOTOR CO.
  3. Tighten the cooler tube nuts.
  4. Lower the vehicle.
  5. Fill the transmission to the specified level with clean automatic transmission fluid.
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