Pulling at 545 tc 200

[Rivetboy]

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

 

[Tango-SKO]

Yes...swap it for a 5 or 6 speed with lockup.

 

[Rusty-SKO]

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.)

 

[Rivetboy]

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

 

[cadillackid]

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

 

[Rivetboy]

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 ...

 

[Booyah45828]

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.

 

[cadillackid]

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

 

[turf]

here is a pretty straight forward service manual to remove and install a 545.

http://www.waghornswood.net.nz/Manuals/Vehicles/Allison_Automatic/Mechanics_tips_at_500_and_at_1500_series_transmissions.pdf

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

good luck!

 

[Rivetboy]

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.

 

[Rivetboy]

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.

 

[Rivetboy]

Hi Christopher

Thanks for having an interest

You know, I did not check. I have decided to replace the trans any how it has 151 k on it and is leaking front and rear and also replace front and rear oil seals with wear kits if neccessary . Then, to pull the injector pump and replace the gasket on the lifters cover.

 

[cadillackid]

I hear that tappet cover is a huge source of leaks.. ..

is the 5.9 not fully supported without a rear X member? on my bus when I swapped trans my Navistar engine was fully mnounted and the trans was mounted only by the bell bolts. I know for a fact that 800 lb trans jack will hold an AT545 with converter as I used the Same jack. I strapped my trans to it with heavy duty ratchet straps.. and it worked well... I unbolted the converter from the flexplate and brought the trans and converter down together.. since the motor is fully mounted it didnt tip forward or back. I kept the trans at a slight rearward angle to not lose the converter.

once I slid the trans back a few inches I bungied across the converter to the bell..

-Christopher

 

[Rivetboy]

I am laughing because I just recieved a package of bungee cords from amazon. I totally agree it can be done and not that hard.
Have the HF 800 lb jack left over from putting a new transmisission in my 2000Chevy 4WD last year so am still warmed up on Trans hassles and adventures thats for sure.

 

[Rivetboy]

The back of the engine is held by mounts on the bell hosing. I will spear an engine hoist through the drivers window and pick up the back of the engine with chains. Then reposition the hoist to pick up the front of the engine to change out the rubber front mount.

 

[Rivetboy]

OK but I think I am going to go the mechanical mt 643 route.
Mt 643 plus a SAE 2 bellhousing and a 398160 flex plate
And of course a crossmember and a mount for that heavy sucker.
What am I forgetting?
Trans cooler in the future and instrumentation too.