Transmission flush and return line identification

Tiny
JIMB2020
  • MEMBER
  • 1996 FORD ASPIRE
  • 1.3L
  • 4 CYL
  • 2WD
  • AUTOMATIC
  • 140,000 MILES
Finally done with engine rebuilding on this little thing! Moving on into the Transmission: I realize there are risks involved when doing Transaxle Fluid Exchange and Flush. First, is there statistical evidence (and what percentage if any) that such procedure could damage it due to "foreign material." Second, recent DIY sources have promoted at home transaxle flushing by collecting the old fluid at the return line while the vehicle is in run mode, shutting off the engine and then refilling the system with new fresh fluid. Do you agree that this alternative procedure is an alternative? Which one is the cooler-radiator return line on this Ford (the connection to the radiator on the right hand side of the car or the left hand side)?
Friday, October 23rd, 2020 AT 7:48 PM

7 Replies

Tiny
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  • MECHANIC
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Flushing the unit is not the issue. That is just fine because all you are doing is exchanging the fluid. I think this whole "rumor" of "do not flush the transmission because it will then fail" got started because most don't understand what is actually happening when you do flush it.

Most all flush machines heat the fluid or require you to do this when the transmission is hot. That is so that the fluid is thinner and will flush out any contaminates with it. The problem is the transmission coolers trap all of these contaminates/metal in it and when you flush the transmission, it does not remove all the contaminates from the cooler. So when you then start driving the vehicle again, those release from the cooler and cause the transmission to fail.

Ford addressed this on rebuilt transmission with the attached TSB but the same theory applies to just flushing the unit.

That brings me to what you should do. I would flush the transmission on a regular basis as it is more effective then just draining and filling. To do this just disconnect both lines from the cooler so that the cooler is not being flushed and use them to attach the machine.

As for using the DIY flush machines, they are just fine. I have even just put the return line in an empty bucket and the supply line in a full bucket and allowed the pump to pull in the new fluid. When the return line ran clean you shut the vehicle off. Clearly this takes some coordination as you don't want to suck air so one of those set ups would be best.

To identify the return line, I would take one of them off and put it in a bucket and start the engine for just a second and see if it shoots some fluid out. Normally the return line is on the passenger side but this manual does not tell us which it is.

If you are rebuilding the transmission I would replace the cooler. If you are not sure about the cooler, I would replace it and flush the unit before installing the new cooler.

Let me know what questions you have with this.
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Saturday, October 24th, 2020 AT 7:20 AM
Tiny
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So, I will drop the pan, replace the filter and gasket and bolt it back up. Refill with fresh fluid. I already have the transmission cooler lines [out (or hot from transaxle) and return (or cooled from radiator)] disconnected because I have a new radiator on this car. I will, then, insert the out (or hot) line into an empty container and the return (or cooled) line into a a fresh fluid-filled container, start the vehicle and let it run until the all fluid through the out (or Hot) line runs clear. I will forget about the use of a machine. Once I am done, I can take it for further inspection and or future Power Flush at Shell, Firestone or comparable Transmission Service Center. Thanks for the additional info regarding the cooler lines and potential damage.
James
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Sunday, October 25th, 2020 AT 3:18 AM
Tiny
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Sounds great. Just make sure your clean fluid bucket stays plenty full. I would suggest having someone stand there, ready with a few extra pints of fluid just in case. This could take between a gallon or two of fluid because it will flush out the converter as well. However, with the fact that you are adding new fluid to the pan, I would think it would go quicker. Last thing just make sure you clip or secure the old fluid line to the bucket. Take from my experience there is nothing worse then to have the line slip out of the bucket and it dumps fluid all over the floor.

Let us know how you make out. One last thing. Just check and top off the fluid when you are finished. There is no guarantee it will fill the pan.
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Sunday, October 25th, 2020 AT 6:10 PM
Tiny
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Hello there, I just wanted to tell you about the transmission flush and how it went. I know this has been a while but here it goes. After following all the directions you provided and whatever I could find at my disposal, something unexpected happened. I tried to be prepared as you mentioned for just about any case scenario, but what happened was that the transmission return line did not suck up any fluid. Luckily, I had changed the filter and gasket and after sealing and bolting the pan back up, I add 3.75 quarts of fresh fluid. I placed a large Mirror up front and sat in the driver seat ready to start the car and to cycle the transmission. It took 3 seconds to see fluid come out into the empty bucket and could not discern any suctioning. Instantly! Engin Off! I checked things out and made some adjustments, checked the fluid level in the pan (almost a quart immediately disappeared, so I replaced that) and started it again: same thing! Instantly! Engine Off! I Replaced what came out with fresh fluid and continued the pattern. Checked the fluid after 12 seconds: Gone but the tip of the dip stick. The empty bucket now has 2 quarts for a total of 3 quarts in 12 seconds. I refilled the pan and continued draining 3/4 to 1 quart at a time and replacing what came out each time. A total of 24 seconds to replace all. Because of the stress level I went through, I somehow lost track of the exact final amount in the transmission after cleaning up and hooking the cooler lines back up. So, I left it alone for an hour and then returned to check the level: It was half to 3/4 full. "Why?" I asked myself: I made sure I was spec. Could it have been that the Torque converter and transmission needed more than 6.3 quarts on dry? But I did not collect more than 6+ quarts at 100% clear fluid at the end of this unexpected procedure? It seemed to me that I was putting in more than what I was collecting. Really strange. At any rate, I was relieved nothing went dry, I added little over half quart and checked the level: over-filled by a hairline. So, What I am wondering here (and please forgive my lack of experience with transaxle fluid replacement) does the transmission pump push fluid though the torque converter and that fluid having had momentum recirculates into the pan? If the answer is yes, then there could be no suctioning at the return line at all. I searched through a forum debate dated April 2009 where a group of mechanics exchanging stories about how risky some of these procedures were, and here I paraphrase some of them: "there could be no suctioning at the return line with Nissans. You have to do the DIY Flush 'one liter in; one liter out until all finished." Then there was arguing about air entrapment due to this method. And the discussion ended with the claim that Air entrapment in automatic transmissions isn't possible with some responders in that forum agreeing. I could not find any additional search results anywhere else. So, that was that. I hope you're having a good new year.

James
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Wednesday, January 20th, 2021 AT 9:00 PM
Tiny
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Just to be clear, you are taking the lines off the cooler? Put the line from the cooler that is returning fluid to the transmission in a bucket of clean fluid. This way the pan is being filled with clean fluid. Then the line that is supplying fluid to the cooler in an empty bucket.

I have not had a transmission get an air lock but in theory it is possible if the pump is not strong enough to pull the fluid out of the bucket. Most all return lines are in the pan so they will be submerged which creates the suction to pull the new fluid out of the bucket. If this is not working then this is what they are talking about doing one quart at a time. Basically you have to fill the pan using the dipstick tube. So you are putting in what comes out. If you do it this way, you only need to remove the line coming from the transmission to the cooler. Hope this make sense.
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Thursday, January 21st, 2021 AT 7:16 PM
Tiny
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You diagram is an outstanding portrayal of the procedure. Thanks. And yes, that was what I ended up doing (return line that was coming out of the cooler going to the transmission pan is now deeply submerged in a container lifted up to the level of the cooler and filled with 4 quarts of fresh transmission fluid and carrying it out to the transmission). However, the line coming out of the transmission into the cooler I did not disconnect. Instead, I let the old warm transmission fluid flow through the cooler and then flow out into a hose I connected to the other end of the cooler and into an empty container (the idea was to flush the cooler on the way out).
That return hose I also had to extend to reach the container but it developed a pich (bending) in it when I looked at it later, so I am not sure if it collapsed at the very beginning. The other possibility (more likely in my case, and I have to say I got lucky that I did not keep it running for more than 1/2 quart at a time) would be exactly what you said 'an air lock or barrier' an empty space in the pan which would've prevented suctioning: meaning my sister must have been driving the car (before she gave it to me to work on it) with 4 quarts of fluid not 6.3. So, the pan was emptying very quickly and there was no way for me to measure the total amount. In fact, I ended up adding two and a half quarts of fluid after the procedure was done. I took it out after the flushing for a test drive and the car was driving with very good shifting. It isn't slipping intermittently she said afterwards. That's what made me think that she didn't have enough fluid and the TCC was acting up on her. Now, it is working great. Thanks for your help. Thanks for the excellent advice I got from you.

James
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Thursday, January 21st, 2021 AT 9:07 PM
Tiny
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Thank you. That is an excellent addition. Thanks for that info as I am sure others will benefit from this in the future. Thanks for using 2CarPros. Please come back next time.
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Friday, January 22nd, 2021 AT 9:40 AM

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