Service Procedure

Figure 1:

Prior to performing this service, it is important to understand that the bypass valve, to function properly, must be located and connected to the transmission oil cooler hoses in the correct oil flow direction (Figure 1).

Figure 2:

1. Using Chrysler Mopar Thread Sealant PN 4318034 or equivalent at all connections, assemble the supplied bypass valve, tees and connectors as shown in Figure 2. Tighten the tees and connectors to 12 N-m (110 in.lbs.).

Figure 3:

2. Raise vehicle on hoist for working access to the transmission oil cooler hoses routed along the inboard side of the left front frame rail.

3. Measure 5-1/2 inches rearward from the front edge of the frame rail and 2 inches up from the bottom of rail (Figure 3) and drill a 1/4 inch diameter hole in the rail.

Figure 4(3-Speed Transmission):

Figure 5(4-Speed Transmission):

4. Referring to Figures 4 and 5, follow the cooler hoses routed from the transmission to clearly identify the cooler "in" hose.

Figure 6:

5. Place an oil pan under the vehicle to catch fluid leakage. (Oil loss will be minimal.)

6. Pushing the cooler hoses against the frame, cut the cooler "in" hose at the drilled hole (Figure 6) and allow oil to drain.

Figure 4(3-Speed Transmission):

Figure 5(4-Speed Transmission):

IMPORTANT: Illustration is typical of 4-speed hose routing. 3-speed hose routing differs; therefore it is important to identify the cooler "in" and "out" hoses per Figures 4 and 5.

Figure 1:

7. Slide 2 of the supplied clamps over the hose ends and install the cooler "in" end connectors of the bypass valve assembly to the cut hose ends.

NOTE: Refer to Figure 1 to identify the male (pipe nipple) end of the valve. This end of the assembly.must be connected to the cooler "in" hose.

Figure 7(3-Speed Transmission Installation):

Figure 8(4-Speed Transmission Installation):

8. Cut the other hose (cooler "out") at the drilled hole, allow oil to drain, and connect the hose ends to the valve assembly connectors in the same manner.

9. Cut the supplied foam tube and wrap it around the bypass valve (Figures 7 and 8).
10. Tighten the supplied "push-in" tie strap around the foam tubing and cut off excess strap.

11. Engage the push-in tie strap in the drilled 1/4 inch hole (Figures 7 and 8).

NOTE: Because the hoses and hose routing differ on the 3-speed and 4- speed transmission, the valve assembly must be positioned differently for each -- valve mounted vertically for the 4-speed and at an angle for the 3- speed.

12. Tighten all hose clamps to 2 N-m (15 in.lbs).

13. Install the other supplied tie strap to secure the assembly to the frame rail (Figures 7 and 8). Cut off excess strap.

14. Check and, if necessary, adjust transmission oil level.