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Cooler Bypass Valve Assembly: Disassembly

NOTE: The cooler bypass valve (CBV) 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: Removing Cooler Line Case Fittings
    G02783972Courtesy of FORD MOTOR CO.
    2. NOTE: Damaged sealing washers will cause transmission fluid to leak at the CBV.
    Fig 2: Removing Rubber-Coated Sealing Washers
    G02783973Courtesy 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 CBV. If the valve assembly is damaged, install a new CBV assembly.
    Fig 3: Inspecting Sealing Ends Of CBV
    G02783974Courtesy of FORD MOTOR CO.
  4. Assemble the CBV and plug the converter-out-to-cooler inlet with a 13 x 1.5 mm (0.06 in) plug.
    Fig 4: Identifying CBV
    G02783975Courtesy 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: Installing Flatwasher
    G02783976Courtesy of FORD MOTOR CO.
  6. Connect the cleaner pressure line to the case converter-out fitting.
    Fig 6: Connecting Cleaner Pressure Line To Case Converter-Out Fitting
    G02783977Courtesy 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
    G02783978Courtesy 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 Proper Solvent Pressure
    G02783979Courtesy 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
    G02783980Courtesy 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
    G02783981Courtesy of FORD MOTOR CO.
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