Radiator In-Tank Fluid Cooler & Line Flushing

The radiator in-tank fluid cooler, remote filter housing and lines must be flushed in conjunction with a transmission complete overhaul. See Figure 88.

Required Equipment: Rotunda Turbo-Tank Heated Cooler Line Flusher.

NOTE:
Plug the flusher into a 110 V outlet and allow up to one hour for it to heat to the proper temperature.

NOTE:
This procedure should be performed when the transmission and the oil-to-air (OTA) cooler are removed from the vehicle.

NOTE:
Do not disconnect the lines from the remote filter. It will be flushed when the lines are flushed.

1. Remove the in-line filter, if applicable, then install a straight pipe with hose clamps in its place.

2. Remove the remote filter and magnet.

3. Clean and reinstall the remote filter housing.

4. Flush the transmission cooler return line first.

a) The transmission cooler return line can be identified as the line that runs from OTA outlet (drivers side) to the rear of the transmission.

b) Using the appropriate fittings and quick disconnects supplied with the flusher, connect the flusher pressure and return lines to either end of the transmission cooler return line.

c) Switch the flusher pump on and allow it to run for 60 seconds.

d) Turn the switch off after 60 seconds and disconnect the pressure line.

e) Blow air through the cooler line until the fluid is drained back into the flusher.

f) Disconnect the flusher return line.

5. Flush the transmission cooler pressure line and radiator in-tank cooler as follows:

a) The pressure line and radiator in-tank cooler must first be back flushed, then forward flushed. This is necessary to thoroughly flush the in-tank cooler.

b) The transmission cooler pressure line can be identified as the line that runs from OTA cooler inlet to the front of the transmission.

c) Using the appropriate fittings and quick disconnects supplied with the flusher, connect the flusher pressure line to the radiator in-tank cooler outlet. Connect the flusher return line to the transmission cooler pressure line (the cooler line near the transmission bellhousing).

d) Switch the flusher pump on and allow it to run for 15 minutes.

e) Turn the switch off after 15 minutes, then reverse the flusher lines.

f) Switch the flusher pump on and allow it to run for 15 minutes.

g) Disconnect the flusher pressure line and blow air through the line until the fluid is drained back into the flusher.

h) Disconnect the flusher return line.

6. Remove the remote filter housing and make sure the small bypass orifice is free of foreign material.

7. Clean the filter magnet and reinstall it along with a new filter.

8. Install the remote filter housing.
Tighten it to 25 Nm (18 lb-ft).

9. Install a new in-line filter or install an in-line filter kit. Refer to Section 307-01B of the 2004 F-SD/Excursion Workshop Manual or 307-01C of the 2004 E-Series workshop Manual for repair instructions.