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Old 08-23-2017, 03:44 PM   #1
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Pulling at 545 tc 200

Hi everyone 1991 tc 200 allison 545 cummins 5.9.
I have to pull transmission to repair oil leak. Anyone done this have any words of wisom
Thanks
Joe7
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Old 08-23-2017, 03:48 PM   #2
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Yes...swap it for a 5 or 6 speed with lockup.
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Old 08-23-2017, 04:05 PM   #3
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Big job. Do you have the new trans or parts to rebuild? Do you have a heavy truck shop?

Did you call for estimates? Never hurts to ask around, may even learn how the pros approach the job.

Where is leak? some leaks can be fixed without pulling (rear pinion, pan gasket, etc.)
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Old 08-23-2017, 06:10 PM   #4
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Transmission is fine engine has bad oil leak either rear oil seal or camshaft freeze plug
Looking to hopefully hear from someone that has done it
Thanks
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Old 08-23-2017, 06:18 PM   #5
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Quote:
Originally Posted by Tango View Post
Yes...swap it for a 5 or 6 speed with lockup.
** THIS **! I did it... big job but now im BIG-RIGGIN..

onto the oil leak.. stiff-wire-brush down the whole engine with a heavy solution of dawn dish liquid (not an off brand) and a little water.. then power-spray it all off.. and start it.. (you can start it with the trans out.. just dont rev it.. it will over-rev quickly without the TC weight as a ballast..

you should be able to see a bad oil leak show up within a few minutes and get a good idea where its coming from.
-Christopher
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Old 08-23-2017, 08:11 PM   #6
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Oil leak

Oh I have figured out where it is coming from, front and rear, tools needed, Cummins part numbers etc. I am just hoping to find someone that has done it
You how, how hard, sequence that worked for them ...
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File Type: jpg oil.jpg (170.4 KB, 11 views)
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Old 08-25-2017, 09:28 AM   #7
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If you're look for a step by step sequence, you probably won't find one. Do you know where the leak is coming from up at front? Do you know where it's coming from in the rear. If it's coming out of the flywheel housing, it's likely the rear main seal on the engine. That's about the only way engine oil will get into the housing.
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Old 08-25-2017, 09:43 AM   #8
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make sure your draft tube isnt clogged, or if you have a draft-recirculation system like a RACOR-3550 make sure it has a clean filter..

if the draft tube is clogged then any blow-by creates positive crank case pressure and the engine would belch oil if the crankcase is under pressure..

when its running do you get smoke out of the draft tube?
-Christopher
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Old 08-25-2017, 10:10 AM   #9
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here is a pretty straight forward service manual to remove and install a 545.

http://www.waghornswood.net.nz/Manua...nsmissions.pdf

in my AT1545 thread i have a link posted for the full service manual too.

good luck!
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Old 08-25-2017, 05:16 PM   #10
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Thanks man!
Here is where I am at a days later..
The continuing saga,

A few years back I fabricated some aircraft jacks for my Piper Cherokee with long stroke Harbor Freight 8 ton jacks. Guess what fits perfectly right at the leaf spring front on the frame?
You got it now I am building jiggery to clamp the Allison to my 800 lb Harbor Freight Trans jack and remove th trans. Am going to stab an engine hoist through the drivers window and chainfall the tail end of the 5.9 up to remove the bell housing and get to the rear engine seal.
Also have decided to install a remanufactured Allison 545 as they are very affordable.
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