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  1. thunder550

    Dowty (bonded seal) washers vs copper washers - converter housing bolts

    Well after doing more reading on the NBR rubber material that comes on the bonded seal washers, it seems like it's only rated for 225-250 degrees F. I'm thinking that's not sufficient for this use case, and I should try what @2004LB7 suggested above...teflon paste on the threads and some RTV...
  2. thunder550

    Dowty (bonded seal) washers vs copper washers - converter housing bolts

    Good info there about the Teflon paste and sealant, I hadn't read any of that. Thank you. Bolts went on dry and torqued to 42 lb-ft. I do find it interesting that it's not just the lower bolts that call for the copper washers that are leaking, but appears to be the next ones up as well. Those...
  3. thunder550

    Dowty (bonded seal) washers vs copper washers - converter housing bolts

    I'm chasing a trans fluid leak coming from the converter housing-to-transmission bolts. I pulled the top of the trans apart already, replaced the two stator/pump plate gaskets, new pump o-ring, new seals on the 10 pump bolts, new copper washers on the bottom two converter housing bolts. Put it...
  4. thunder550

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

    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...
  5. thunder550

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

    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...
  6. thunder550

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

    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.
  7. thunder550

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

    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...
  8. thunder550

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

    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...
  9. thunder550

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

    No, only replaced gaskets and seals.
  10. thunder550

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

    Truck is back on the road as of this morning. Put about 50 miles on it, so far so good...
  11. thunder550

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

    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 ?
  12. thunder550

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

    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.
  13. thunder550

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

    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...
  14. thunder550

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

    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?
  15. thunder550

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

    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.
  16. thunder550

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

    It's definitely tempting....lol
  17. thunder550

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

    Will do. Are these the two you're talking about? One showing, and one hidden under the extension housing seal?
  18. thunder550

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

    Went ahead and ordered the two bellhousing/stator gaskets and the large pump o-ring as well, don't want to have to do this twice.
  19. thunder550

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

    Ordered an input shaft seal, 10 o-rings, 2 copper washers, and a Merchant pump rub kit. Since the converter and the area under the snout are dry, I don't think there's an issue with the pump o-ring, so don't want to mess with removing the bell housing to replace. Pulling transmissions is my...
  20. thunder550

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

    Thanks James, the line pressure thing must have been a rumor or something I read on the internet. You know if it's on the internet it must be true :LOL: I've read other forums where people have had the bolts leak around the o-rings, but I'm far from knowledgeable on transmission stuff.
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