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You could replace them with one that has no handle making it much harder to remove: https://www.petersenproducts.com/143-2-Series-T-Handle-Expandable-Rubber-Plugs-s/1898.htm Find the right size unit that just has a nut and then you'll be able to really crank it down with a wrench and without...

It was WAY at the wrong angle when I tried that. Have you tried these on a C7 before? Could just be my truck. Works great how I remade it. 🤷‍♂️ Perhaps it's the newer style transmission cooler bracket attached to the same engine mount.....

I don't have an explanation of that. It's not practice at the unit level to mark such a bolt AFAIK. Sadly the military isn't even going to get inside a transmission at the unit maintenance level (my direct experience). The military will simply swap the entire transmission assembly with a new or...

I agree. I'm a Motorpool veteran and a former software engineer and I currently own a performance shop building race cars and chassis dyno tuning, etc. No hands other than my own have ever touched my truck. If that's the situation then I would leave it till the money situation improves or...

I actually got the correct Red-Dot hoses for mine but that also required that I change to a different dryer and also to a different trinary switch and had to track down an obscure adapter to get that all to work together because the Red Dot dryer has different ports and the stock Red Dot /...

......This is not the truck to own or even consider buying in the first place if that is your budgetary situation. My only advice at that point is to sell the truck and buy one again when you have the means to pursue this type of project. Next time - whatever you pay for the truck - have at...

If you can pull the cover with the transmission installed I would definitely do that to gain more perspective and information.

Interesting post dealing with the issue you are potentially dealing with. Looks like Allison changed the bearing to a "composite bushing".... lots of details if you are experiencing this issue: https://www.steelsoldiers.com/threads/m1078-a1-transfer-case.195212/

The summary to what Ronmar just posted is: "Install a new or remanufactured transmission" if you need this thing road-worthy in the short term. Or find a VERY WELL QUALIFIED Allison rebuild shop and pull the transmission/t-case for them or have them do it. My sources in the military say they...

No - tapered roller bearing - I mean yeah they have a thrust component to what they do but it's not what most people think of when you say "thrust bearing"..... Bearing cage: They come in thousands of sizes - they are integral to the bearing and generally aren't removable on their own...

Still reminds me of a section of a bearing cage. Send a sample of the oil in for analysis.

Looks like part of a bearing cage to me. I would clean them better and try to get a closer look. Digital microscope would be handy if you happen to have one or know someone that has one (used often in electronics repair). Also send some of the old fluid for analysis. What else was on the...

12 might be a stretch but those of us doing the direct drive hubs are getting over 10-11 at freeway speeds.

Ohm them to the PPD/LBCD terminal lugs with the battery cables disconnected at both ends.

At the first signs of lower than normal oil pressure or especially if you get that oil pressure idiot light it's time to drop the pan and replace the pump. The job isn't that bad but it's enough labor and enough expense in oil, filter, and time that to simply inspect it would be a waste. You get...

The usual surplus suspects for the seals and shim kit. To properly torque the spindle nut you need a rather oddball socket - 3-7/8" Eight Point extra deep - that really isn't available to buy since it's made special for the military by OTC...

The CTIS seals rotate on the spindle and simply cycling the CTIS while stationary is not a sufficient test. Pull the banjo bolts for the CTIS valve off the wheel stud and smell for gear oil. Have you done a wheel bearing service? The inner wheel bearings are supposed to be repacked, torqued...

Yeah that's possible. I would guess that any 15w40 would be fine. It's not like the transmission is dealing with combustion products.

I wouldn't. The military currently uses 15w40 in trucks that were shipped with it. Newer trucks are shipping with ATF (these are all Allison 3700SP transmissions not the older 3070SP) and the Army is servicing these with synthetic Dex IV. From what I can tell the Toyota T-IV is only equivalent...

Initial costs after purchase or ongoing costs once everything is sorted out? Initial costs can be absolutely enormous. Often eclipsing the cost of the truck itself (for example if you want BRAND NEW tires @ $10,000 - $14,000 from Goodyear depending on LMTV/MTV). It really depends on which...