2006 Allison 6 spd: Trans pump bolt gaskets and copper washers?

[thunder550]

Well it sorta fits in the garage...it's up as far as it will go while still allowing the garage door to open. Anyone know off-hand how tall the Allison is from pan to peak of bellhousing? Trying to figure out if I'll be able to get it out from under the truck.

 

[thunder550]

She's out.


The round connector at the back of the trans is full of fluid...is there a seal I need to replace, or does the whole internal harness need to be replaced?

 

[Chevy1925]

She's out. View attachment 104705
View attachment 104704

The round connector at the back of the trans is full of fluid...is there a seal I need to replace, or does the whole internal harness need to be replaced?

Merchant or somewhere else has just the seal but the harness can be done just as easy. Only place I found in town for the whole harness was transtar near down town. Otherwise amazon is your best/cheapest (rockauto might be too).

 

[thunder550]

Merchant or somewhere else has just the seal but the harness can be done just as easy. Only place I found in town for the whole harness was transtar near down town. Otherwise amazon is your best/cheapest (rockauto might be too).

I've been trying to find how the Merchant seals work. Looks like they offer just a seal, and a seal with internal connector body. Can't find videos or instructions for installation on either one...connector body obviously goes on from inside the pan, but does the seal install from the outside? If I don't have to open the pan I won't...but if I do have to open the pan, I need a new gasket and might as well do the internal filter as well.

 

[thunder550]

I found a couple of threads here on DD where it looks like the Merchant seals have mixed results. Went ahead and ordered the whole harness, along with a few other odds and ends I needed.

 

[Chevy1925]

I've been trying to find how the Merchant seals work. Looks like they offer just a seal, and a seal with internal connector body. Can't find videos or instructions for installation on either one...connector body obviously goes on from inside the pan, but does the seal install from the outside? If I don't have to open the pan I won't...but if I do have to open the pan, I need a new gasket and might as well do the internal filter as well.

yeah pan has to come off for you to change out the harness. its really simple though, just do it when its back in the truck. use a big socket to collapse the clips that holds the connector into the trans and knock it out. think its like a 30mm or something that fits it.

 

[thunder550]

yeah pan has to come off for you to change out the harness. its really simple though, just do it when its back in the truck. use a big socket to collapse the clips that holds the connector into the trans and knock it out. think its like a 30mm or something that fits it.

Thanks James.

Got the bellhousing and stator assembly apart, bushings both look good. Still have the orange coating intact on the inside. Got everything cleaned up and started putting back together. Not as bad as I thought it would be. Hopefully nothing leaks after this

 

[thunder550]

Truck is back on the road as of this morning. Put about 50 miles on it, so far so good...

 

[PureHybrid]

Do any tweaks while the pump was off?

 

[thunder550]

Do any tweaks while the pump was off?

No, only replaced gaskets and seals.

 

[48548]

Just wanted to say nice to see someone else on north valley area... I am at grovers and 44th st.... I have a tech 2 if someone ever needed help...

Michael

Sent from my SM-N975U using Tapatalk

 

[thunder550]

Well after towing our boat around about 100 miles yesterday, it's still leaking. Stuck my borescope up there and there are fluid rings around a few of the bolts with the rubber gaskets. I was able to soak up a little bit from the bottom of the bellhousing by sticking a paper towel in through the small round inspection hole and moving it around with my finger. I'm at a loss. The rubber seals were all new. I torqued everything to 42lb-ft. Any ideas?

Just wanted to say nice to see someone else on north valley area... I am at grovers and 44th st.... I have a tech 2 if someone ever needed help...

Michael

Sent from my SM-N975U using Tapatalk

You're right down the street from me, I'm just east of Tatum a couple streets north of Grovers.

 

[Chevy1925]

pics show the bellhousing rrreeeallll wet around where it mates to the trans. sure its not leaking at the top and coming down?

 

[thunder550]

pics show the bellhousing rrreeeallll wet around where it mates to the trans. sure its not leaking at the top and coming down?

I replaced both of those gaskets and it's now dry on the outside. Could those gaskets allow trans fluid to get inside the bellhousing? Seems like fluid inside the bellhousing would have to originate inside. Only way I can see for fluid to get inside would be a bolt o-ring leak, converter snout seal leak, or pump o-ring leak. Maybe I'm missing something?

 

[thunder550]

The two bolts that I can see fluid coming out around are the two circled in pink/purple in the attached pic (ignore the red line). I stole this pic from the interwebs, it's not mine BTW. Just using it to show the two wet ones I see.

 

[thunder550]

Realizing now that the two bolts I circled do not have o-rings on them since they hold the bellhousing to the transmission, and are not attached to the pump. Have any of you seen these ones leak before? If I'm not mistaken, they thread into the transmission holes circled in red below...

 

[thunder550]

Poked around with the borescope again today. Looks like the two I circled above, along with the two that take the copper washers, are all leaking. What the hell. @Mike L. have you seen this happen before? Was 42lb-ft not enough torque?

Bolts pictured below are numbered as in this pic:


1


2


3


4 (this one looks dry now but last time I looked it had a red ring around it)

 

[Conner]

Were you able to figure out what was going on with those bolts?? I have mine apart right now was planning on changing the same stuff you did

 

[Conner]

maybe copper washers for all 4? I wouldn't think any should leak if the gasket is seated right on the plate? I didn't look into my tranny with a camera before I pulled as I don't have one but there was 2 lines around the inside of the bellhousing where it almost looked as if oil was being sprayed off the torque convertor

 

[Bdsankey]

Poked around with the borescope again today. Looks like the two I circled above, along with the two that take the copper washers, are all leaking. What the hell. @Mike L. have you seen this happen before? Was 42lb-ft not enough torque?

Bolts pictured below are numbered as in this pic:
View attachment 104753

The spec IIRC is 37 ft-lbs not 42 ft-lbs

maybe copper washers for all 4? I wouldn't think any should leak if the gasket is seated right on the plate? I didn't look into my tranny with a camera before I pulled as I don't have one but there was 2 lines around the inside of the bellhousing where it almost looked as if oil was being sprayed off the torque convertor

Only bolts 2 and 3 in his image receive copper washers from Allison. I have never seen them leak like his while using proper gaskets and clean assembly.