Allison 6sp: Converter snout failure?

[JDPlowboy]

Truck wouldn't build line pressure so i dropped Trans and went to pull converter out and it wouldn't come all the way out, at the very end when I felt like it was about to pull out it would get wedged somewhere. Well I tried all day to get it out.

I ended up busting up bell housing and getting the bolts out to separate it from Trans case. Then I had to torch snout of converter off to get it separated. The pump gears were broken and fell out after I got converter off and pump separated.

Any ideas to why this happened?

And does anyone have a core 6 speed? I just need from stator forward.

 

[JoshH]

How long was the transmission in the truck? This can happen during installation if the converter isn't fully seated when the trans is bolted to the engine, but it would be a problem right away, not something that developed over time.

 

[JDPlowboy]

5k miles. I had problems with it the first time I put it in. Put in a brand new pump from Allison and as soon as I started the truck it blew up.

Pulled Trans back out and it kinda marred up the snout so I took emry cloth and smoothed it back up till it slid easy on a new pump gear. Put another new pump in and was good to go. Pump housing bolts were torqued to 20#'s each time

 

[JDPlowboy]

I'm betting there wasn't enough play on the snout at pump gear and it swelled some more and popped pump gear again.