Cooler Bypass Valve Assembly: Disassembly

WARNING: This page is about a different car, the 2003 Ford RV Cutaway, 2003 Ford Econoline, 2003 Ford E550 Super Duty, 2003 Ford E450 Super Duty, and 2003 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.

Remove and inspect the cooler line case fittings. If the cooler line case fittings are damaged replace the cooler line case fittings.

Fig 1: Removing Cooler Line Case Fittings
Courtesy of FORD MOTOR CO.

NOTE: Damaged sealing washers will cause transmission fluid to leak at the cooler bypass valve.

Fig 2: Removing Rubber-Coated Sealing Washers

Courtesy of FORD MOTOR CO.

Remove the rubber-coated sealing washers and discard.
Inspect the sealing ends of the cooler bypass valve. If the valve assembly is damaged replace the coolant bypass valve assembly.

Fig 3: Inspecting Sealing Ends Of Cooler Bypass Valve
Courtesy of FORD MOTOR CO.
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: Installing Cooler Bypass Valve And Plug Converter-Out-To-Cooler Inlet
Courtesy of FORD MOTOR CO.
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
Courtesy of FORD MOTOR CO.
Connect the cleaner pressure line to the case converter-out fitting.

Fig 6: Connecting Cleaner Pressure Line To Case Converter-Out Fitting
Courtesy of FORD MOTOR CO.

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

Courtesy of FORD MOTOR CO.

Place the CBV into the solvent tank.

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 Solvent Pressure Tool

Courtesy of FORD MOTOR CO.

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.
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
Courtesy of FORD MOTOR CO.
Using 344.75-620.55 kPa (50-90 psi) of regulated compressed air, blow through the CBV until all solvent is removed.
Remove the plug from the CBV converter-out-to-cooler inlet.

Fig 10: Removing Plug From CBV Converter-Out-To-Cooler Inlet
Courtesy of FORD MOTOR CO.