Allison 6sp: Lots of Codes and Possibly A Leak

bml2200

Member
Oct 16, 2008
256
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16
IL
Limped the transmission today with the codes:
P0700- general trans malfunction
P0751- 1-2 shift solenoid
P0762- 4-5 shift solenoid
P0873- Trans fluid switch 3
P0877- Trans fluid switch 4

FWIW, on tune 4 with the 07 LBZ in the sig I was accelerating from a stop merging when this happened.

I did a search and it seems like the most probable cause was low fluid (which makes sense when you read below).

Background: Transmission is stock with 194k miles. Only 2000 miles have been with the mods, the other 192k it was stock. I replaced the transfer case yesterday since the previous one was of victim of pump rub and trashed everything. A few weeks ago before I noticed the hole in the tcase, the truck did a harsh 1-2 shift in the morning and didn't do it again. I attributed it to the transfer case but then it happened again this morning.

Once I checked the codes and cleared them I went home and checked the fluid. It was up to the cold level on the dipstick. I crawled underneath the truck and the transfer case wasn't leaking anywhere, not at the trans gasket or output seal. However, I noticed what looks like trans fluid on the lip of the bell housing and a spot or two on the front driveshaft (which had none on it the day before). I pulled the inspection plate because there was some fluid by it but everything inside looked dry and seems to have gotten on it from externally of the trans.

A few thoughts I had, there has been an issue with the trans all along in addition to the transfer case being bad. The harsh 1-2 shift in the morning was caused by the fluid being cold/low. As for the fluid spraying, one explanation could be that I overfilled the tcase a little and it is coming out of the breather or worse the trans is leaking into the tcase and filling it up.

Any ideas? Thanks.
 

bml2200

Member
Oct 16, 2008
256
0
16
IL
Added 1.5qts and it shifted fine this morning. Still wondering where it could be leaking though.
 

bml2200

Member
Oct 16, 2008
256
0
16
IL
Pull the fill plug on the TC and see if it's over full.

I pulled the plug and a few drips came out but that was it. Here are a few pictures:
photo1-1.jpg

photo2-1.jpg
 

bml2200

Member
Oct 16, 2008
256
0
16
IL
Update: Parked the truck for a couple weeks, finally took another look at it. The leak was antifreeze coming from the heater hose going from firewall to the hard line on the passenger side middle of the engine. This was a new hose used to delete the egr. I had reused the spring tension clamp, it would barely leak at idle but spray a good amount when revved. Swapped the spring clamp with a worm gear type and no more leak.