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Allison OEM Discuss repairing & maintaining an OEM Allison automatic transmission.


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Old 02-06-2020, 08:53 PM   #1 (permalink)
shirazdrum
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Stranded please help - ATF gushing out of the Allison 1000

Hi guys,

I'm in a middle of nowhere (Brazil) and need to fix this truck before the weekend as I'm traveling.

The truck is a 2005 LLY and it has an Allison 1000 tranny. About 2 months ago, it started to pour ATF from the inspection hole and based on everything I read here, I changed the front pump seal, put the tranny back on and the second I started the truck it started to leak again. I took it apart, and this time changed the seal, O-ring, bushing, stator support bushing, bolt o-rings, copper washers and gaskets. No more leaks.

I drove it 600 miles from Paraguay to Brazil and everything was bone dry. I started the truck this morning and drove out of the driveway and parked on the side of the road and here it was again, pouring fluid (gallon a minute to give you an idea) from the same place again. Worth noting that I looked under the truck and there wasn't even drop of oil before I started it.

It can't possibly be the seal, I'm no automatic transmission expert but I know that rubber oil seals are not designed for high pressure applications. Something is pushing the fluid past the seal from the inside. And rubber seals don't start leaking all of a sudden for no reason.

Looking at the manual for the 1000, I see three valves behind the pump, pressure relief valve, regulator valve,... Could any of these valves sticking or not opening cause this problem? What else could cause high pressure in that area behind the seal?

I towed the truck to a shop with lift and since I've taken out this damn transmission 3 times I won't have any problem taking it out again tomorrow morning but throwing another seal at it sounds crazy to me. The mechanics are not gonna touch it, I'll be doing the work using their facility so please help me out here, I'm stuck and hell I don't even speak Portuguese.

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2005 Duramax LLY
Base Model

Last edited by OkDually; 02-06-2020 at 10:08 PM. Reason: prefix adj
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Old 02-06-2020, 09:56 PM   #2 (permalink)
shirazdrum
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Forgot to mention, I pressure tested the converter as well and it was fine.

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2005 Duramax LLY
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