DIY Transmission Fluid Exchange on Ford TorqShift Transmissions

DIY Transmission Fluid
Exchange on Ford TorqShift
Transmissions
How to build and use a heated and
pressurized system to exchange fluid
in automatic transmissions
Prepared by greasyfingers, forum member on www.thedieselstop.com.
For educational use only; author takes no responsibility for the completeness
and accuracy of the contents
Problem
• 2006 Ford F-350 with TorqShift 5r110W
automatic transmission holds 17.5 qts of
fluid between the transmission, torque
converter, lines, and coolers
• Draining the pan only replaces 7.5 qts,
leaving the bulk of the old fluid trapped in
the torque converter and coolers
Common Solution
• On typical automatic transmissions, a cooler line
flush (or, better termed “exchange”) is performed
by the DIYer by starting the engine with one of
the external fluid cooler lines disconnected and
directed into a bucket
• As old fluid comes out the line, new fluid is
poured into the dipstick filler tube until the fluid
runs clear
• This method usually pumps the old fluid out of
the torque converter, providing a complete
exchange of the old fluid
Why a simple cooler line exchange
doesn’t work for the TorqShift
transmission
• There is an internal temperature regulator that
limits the external flow to the cooler until the fluid
temp reaches operating temperature (~160 deg)
• Even at operating temp, the cooler line flush
procedure will not work, since the fresh fluid
being poured into the dipstick is cold, and
cannot keep up with the rate at which old fluid is
being pumped out when the regulator opens
• The torque convertor will not be flushed if
attempting this procedure cold
Professional Solutions
• Ford dealers and service garages may have the
heated fluid exhange equipment to connect to
the cooler lines that will automatically exchange
the old fluid with new fluid
• The service is costly
• Mechanics have been known to incorrectly
perform this maintenance, or have no
knowledge of it (the Ford factory service manual
does not specify the requirement to exchange
the fluid while at operating temperature)
The DIY Solution:
• Heated reservoir of
18 qts
• With air pressure
applied, heated fluid
is forced into the
transmission as fast
as it is pumped out
How it’s made:
• Starts with a 5gallon capacity
pressure vessel
(old 20-lb propane
tank works well)
How it’s madeModify the tank
•
•
•
•
Completely empty the tank
Remove fill valve
Purge LP gas out of tank!
Drill holes where needed for adding
pipe fittings
• Weld threaded bosses to tank for fill port,
heating element, and temperature probe
How it’s madeInstall Components
• Assemble pipe
fittings for fill port,
drain port, sight
gauge, air inlet, and
temperature probe
• Air test,
and
hydro test
welds for
leaks
How it’s madeInstall Components, cont’d
• Install electric water heater element
• Mount thermostat to side of tank, just
higher than the element
How it’s madeMounting
• Attach tank to a suitable base, a plywood
base in this case
How it’s madeInsulation
• To warm up faster, and
prevent contact with hot
surfaces, wrap the
completed tank in
insulation.
How it’s madeWiring
• Wire the thermostat to
the heating element
• Control the power to the
thermostat with a switch
• Add indicator lights to tell
when there is power to
the thermostat, and
when the thermostat is
closed (actively heating)
• Connect a power cord
with grounded plug,
rated for 15A
Vehicle Modifications
• Locate cooler return line to transmission
• Cut pipe, install flare nuts, and flare ends
of pipes
Install a union
in the line
during normal
use
Exchange Instructions
• Preparation of Exchange Rig
• Preparation of Vehicle
• Exchange Procedure
Exchange InstructionsPreparation of Exchange Rig
1.
2.
3.
4.
5.
6.
7.
Fill exchange rig with new transmission fluid, per
manufacturer’s specs
Add one extra quart over the transmission capacity
(18.5 qts for TorqShift)
Power up the exchange rig heater element
Monitor temperature (~1/2 hr for 18.5 qts)
Swirl the tank to ensure even heating since the fluid
below the element will not warm up quickly
Adjust thermostat to maintain 170-180 deg
Connect air supply with regulator set at 30 psi max
Exchange InstructionsPreparation of Vehicle
8. Engage parking brake, chock wheels
9. Run engine in gear until transmission
and engine are at normal operating
temperature (middle of the gauges)
10. Shut off engine
11. Immediately initiate the following steps
before transmission cools off:
Exchange InstructionsExchange Procedure
12. Drain oil in the transmission pan by
removing the drain plug. Replace plug
13. Pour fluid into discharge bucket and
make note of amount of fluid
Exchange InstructionsExchange Procedure – Final connections to
vehicle
14. Connect elbow fittings
to flares
15. Run discharge hose
into discharge bucket
16. Connect return hose to
drain valve on rig
Exchange InstructionsExchange Procedure – cont’d
17.
18.
19.
Restart engine
Put into gear
As fluid flows out of transmission discharge hose into discharge bucket, adjust
drain valve on rig to match that flow into the transmission. A design flaw with this sight gauge design
draws air into the line due to a venturi effect, so an added shutoff valve must be closed on the gauge when draining the rig.
20.
When the bucket has 17.5 qts of fluid in it, shut off the engine and the rig.
21.
Caution! Do not over-fill transmission, or fluid will come out the overflow
and/or dipstick tube. It is best to fill slower than the oil is pumped out, but
not to allow the oil pan to go dry.
When nearly all fluid has drained from the rig, watch for air in the drain
line and immediately shut off the valve, or pressurized air will violently
blow fluid out the overflow and dipstick tubes on the transmision.
Shut off the engine when volume of drained fluid in discharge bucket
reaches 17.5 qts.
Replace remote filter element.
22.
23.
24.
25.
Remove the rig hoses and reinstall the union in the transmission cooler return line.
Restart vehicle, check for leaks in the union, and adjust fluid level on the dipstick
with transmission in Park, and at normal operating temperature.