PTC converter swap, now huge oil leak

[hemi8]

Installed my new 9.5" PTC NL converter this weekend, everything was fine with my Vigilante lock-up. I ran the car for about half an hour with the PTC and all was well. Went to go to work this morning and there was a huge puddle under the car, it was not leaking while it was running that I could to tell yesterday, only when it sat overnight. The tranny is a TCI with a BRF valvebody and was fine before the install. It looked like it was dripping out of the front of the Hughes pan, but I doubt the new gasket is bad, so I removed the inspection cover and am going to install a new new pan gasket, fill it and try again as I just cannot tell if its comming from the front seal area. Wouldn't a bad front seal/bushing leak/cracked converter snout leak while the car is running?
The converter holes (2 out of 3) not lining up perfect with the JW flywheel pissed me off to start with, if this thing is the cause of this terrible leak I'll put my Vigilate back in, what a waste of time. Any advise appreciated.
Mike

 

[Firechaser]

Did you definitely get the 3rd click while seating the converter? I remember they can be a little tricky when installing....I thought I had mine set correct and fortunately I had someone more experienced w/ me and he showed me it wasnt set correct. As for the CAT flywheel lining up, mine was the same...I believe this is common, just need to hog the holes out a tad. hope you get it sorted!

 

[SSedan64]

When the engines running the Trans fluid level will be about even with the pan mounting surface. After sitting for a while the TC/TorqueConverter will drain back into the pan raising the fluid level. It's possible the pan gasket isn't sealed properly. You're correct about a front seal leaking while running.
If the vehicle has sat for very long Dirt Dabbers can plug the vent tube on top of Trans & cause leaks when the pressure builds from heat.

 

[jasjamz]

You may have knocked the spring off the seal putting the converter in. You did install a new seal in the front pump right? Always bolt the converter up before instsllind the trans. This will allow you to see if the bolts fit and if not you have all the room in the world to open them up with no trans in the car. If you purchased it new, the instructions stated all of this. Was your Vigilante a lock up?

 

[bison]

Ive never had a ptc not line up and I've installed over 20 of them. There is usually one hole that is too small and requires opening up. A leak like you describe should be easy to locate. Spray the entire area with brake parts cleaner and watch for the oil to leak out.

 

[stovebolt 34]

When changing over to the 200-4r from the th 350 the flex plate holes had to be hogged out slightly with a chain saw file .

X2 on the Georgia dirt dobbers .

 

[Dusty Bradford]

The holes in the flex plate should be drilled out slightly because the stock size holes are a very tight fit for the larger bolts.

The area prone to leaking is around the snout area that goes inside the transmission. These are prone to crack where the pump drive slots are notched in the snout. See if you can determine if the seal is the issue or if it's coming from the snout or possibly even where the snout is welded to the front of the converter. I have never figured out why the 200's are so prone to having this issue with the cracking of the snout. The 350's and 400's don't have this problem.

 

[hemi8]

Thanks for all the wisdom, wish I knew this stuff before I began, I had to order a new pan gasket as nobody seems to carry one. I removed the inspection cover and I went over the whole pump face and I do not see any fluid trails, I am truly hoping it was the gasket. The entire outside case is completely dry above the pan rails. The pan is a Hughes and it came with a composite gasket, the one I installed this time was a rubber NAPA gasket so I don't know, maybe it did not like the rubber gasket? I am going to install a new felpro gasket, fill it up and run it again with the inspection cover off for a birds eye view. Yes, the Vigilante was a LU so I did the mods needed to change it to a NL converter. I should have held the converter up to the flywheel before installing the trans, just didn't occur to me. I did not install a new front seal and I would not drop the trans to put on a new one. If its leaking from the front seal area I will install a whole new pump, I sure hope its coming from the gasket.
Mike

 

[stovebolt 34]

I've had the stock pan off at least 3 times this year for one reason or another and reused the same rubber gasket . Put on dry (no sealer ) . torque the bolts to 120 inch lbs . No leaks .

 

[hemi8]

Installed the new gasket, dry, 120 in-lb, ran it and filled it, got it up to temp and shut it down. Since I have the inspection cover off its easy to see the front seal area. I can see a little wetness where that big metal clip sits over the front seal but it does not appear to be dripping. I'll let it sit overnight and see if it fills the garage with fluid again. It seems like if it were to drip from the front seal it would do it while running?
Mike

 

[hemi8]

No leak overnight, so while I was doing a couple other adjustments I raised the rear of the car and the fluid started pouring out..........from a bad TV cable rubber seal! I am glad its a simple fix! I am surprised nobody, including the GM dealers, carry this part, they all have to order it, so I'll sit and wait till Monday afternoon. NAPA part#ATP-17154, GM#25518260. Just glad I don't have to pull the trans! So the pan gasket was fine all along.
Mike