Repair Procedure:

This repair involves the installation of a pressure actuated bypass valve that will bypass the transmission cooler if it becomes restricted.

Figure 1:

NOTE: THE BYPASS VALVE IS DIRECTIONAL, IF IT IS NOT CONNECTED TO THE TRANSMISSION OIL COOLER HOSES IN THE CORRECT OIL FLOW DIRECTION --- THE BYPASS VALVE WILL NOT FUNCTION. FIGURE 1.

Figure 2:

1. Using thread sealer at all connections, assemble the supplied bypass valve, tees, and connectors as shown in Figure 2.
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.

Figure 3:

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

4. Referring to Figure 3, follow the cooler hoses routed from the transmission to clearly identify the cooler "in" (to cooler) hose.

Figure 4:

5. Install the bypass valve as follows:

FOR AC AND AY BODIES WITHOUT BENDIX ABS

^ Measure 2-1/2 inches up from the bottom of the frame as shown in Figure 4 and drill a 1/4 inch hole.

^ Pushing the cooler hoses against the frame, cut the cooler "in" (to cooler) hose at the drilled hole (Figure 4) and allow oil to drain.

^ NOTE: THE HOSES ARE BANDED TOGETHER WITH TAPE AT SEVERAL LOCATIONS. UNWRAP TAPE BANDS, AS REQUIRED, TO ALLOW HOSE FLEXIBILITY FOR CONNECTION TO THE BYPASS VALVE ASSEMBLY.

^ Slide two of the supplied clamps over the hose ends and install the cooler "in" (to cooler) and 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" (TO COOLER) HOSE.

Cut the other hose, cooler "out" (from cooler) at the drilled hole, allow oil to drain, and connect the hose ends to the valve assembly connectors in the same manner.
^ Cut the supplied foam tube and wrap it around the bypass valve.

^ Tighten the supplied "push-in" tie strap around the foam tubing and cut off excess strap.

Figure 5:

^ Engage the push-in tie strap into the drilled 1/4 inch hole (Figure 5).

NOTE: THE VALVE ASSEMBLY MUST BE POSITIONED VERTICALLY.

^ Tighten all hose clamps.
^ Install the other supplied tie strap to secure the assembly to the frame rail (Figure 5). Cut off excess strap.

Figure 6:

FOR AC AND AY BODIES WITH BENDIX ABS

INSTALLATION OF THE VALVE IS THE SAME AS ABOVE EXCEPT AS FOLLOWS:

THE EXISTING COOLER HOSES ARE RETAINED BY A CLIP AT THE ABS MODULE (FIGURE 6). DRILLING OF A HOLE IS NOT REQUIRED.

^ Mark the hoses at the rear edge of the clip.

^ Remove the clip.

^ Cut the hoses at the marks.

^ Install the valve assembly and tighten the clamps.

Figure 7:

^ Reinstall the clip to support the valve and hose assembly as shown in figure 7.

Figure 8:

FOR AS BODY

INSTALLATION OF THE VALVE IS THE SAME AS THE AC/AY BODIES EXCEPT AS FOLLOWS:

DRILLING OF A HOLE IS NOT REQUIRED.

^ Cut the cooler hoses in line with with the center of the large hole in the bottom of the frame, figure 8.

^ Install bracket PN 4333568 to retain the upper cooler hose, using the existing lower battery tray attaching bolt as shown in figure 8.

NOTE: SINCE THE VALVE ASSEMBLY WILL BE CLEAR OF THE FRAME RAIL WITH THIS INSTALLATION, THE ANTI-RATTLE FOAM TAPE AND TIE STRAP ARE NOT REQUIRED.

^ Install the valve assembly and tighten the clamps.

^ Position the valve and hose assembly in the clip as shown in figure 8.
6. Check and adjust transmission oil level as necessary.


POLICY: Reimbursable within the provisions of the warranty.