2002 Ford Super Duty F-250 - The Perfect Upgrade

One of the advantages of a BTS transmission is the inclusion of an upgraded steel tailhousing to replace the cast-aluminum factory part. In a matter of minutes, the transmission was attached to the transfer case. The crossmember used to mount the transfer case was reinstalled, and the transmission was hooked to the factory wiring harness in just a few steps.

After the new torque converter was filled with fluid and reattached to the 4R100, it was staged for installation into the Super Duty. The fit looked good, so the South Bay crew attached the transmission to the engine bellhousing but kept the jack in place until the transmission was totally secured.

The transmission cooler lines were cleared with brake cleaner and compressed air to remove any leftover burned fluid in the system. Next, the high-capacity pan was reinstalled on the BTS transmission using the supplied gasket. The torque converter was then filled with ATF before it was hooked to the new gearbox.

This is the upgrade everyone has been waiting for (yes, we got all your letters when the story was delayed). Installation of the 6.0L transmission cooler is fairly simple. You'll need a couple of 3/8-inch to 1/2-inch brass adapters because the 6.0L cooler uses larger fittings than the 7.3L. Just apply some Teflon tape and screw on the adapters, and you'll be ready to tap into the stock transmission lines. We used a 90-degree bend adapter (arrow) on the driver side to keep the line out of harm's way. The cooler slides into place behind the air-conditioning condenser and screws into the same holes used by the stubby 7.3L part. Congratulations, you now have a transmission cooler that can flow about 136 percent more ATF.

With the BTS 4R100 and billet torque converter in place, along with the new higher-capacity 6.0L transmission cooler, our Super Duty diesel is ready for some dependable rock-bashing, mud-bogging, and daily-driving fun.