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Sounds like either a bad air manifold , or bad output clutch. but my money is on manifold.

Lube only. No alcohol! !!

See post 34. I told you about the disconnect.

Well the regulator locks the rear clutch at different psi for different gears. So if you want a solid answer. I need to know the presure on the output to the rear clutch which I provided a picture of where it is located at.

My money is on the rear clutch pack as its the only of the 2 that's regulated and also the primary 1 to fail or act up. If your locking up hard up to 10th gear. Than its the regulator in the manifold.

Welcome to the forum !!! The trans uses 10 wt. I use 15-40 myself. The trans is part hydraulic, and mostly air actuated. Unfortunately most of the O rings in these old units get dried out, Crack or break. They can be finicky if there not set up right ! In the picture you can see the little gauge...

Yes you definitely don't want to drive it like that or you will burn up the clutches. Let's try the simple first. Go to your passanger air tank the 1 most out board. With the truck not running and all the air bled down. Remove the airline from the back of the tank and fill it with air tool oil...

Sounds like your clutch regulator on your manifold is not set up right. There are 4 pressure ranges for 4 groups of gears. High gears use the least amount of pressure . Your allowed +2 psi or -2 psi or it doesn't work correctly . Also if you went down any step grades and the engine rpm exceeded...

Cat still sells the manual.

Unless you used some sort of thick oil. It didn't mess up your manifold. Most of these were made in 1980 ( 32 years ago) there all on borrowed time til they need a rebuild)

Sounds like you manifold needs a rebuild.

Yes that is indeed the ring . It seal very well on all sides. Its a bit stiff once assembled and you apply air. But I found a trick to get them all in line and they are so far flawless. I have ove 20 hrs of test on the first 1 and about 15 on the second unit and about the same on the 3rd. I use...

Cat has it as a 5P-8942 , I actually use whats known as a double O ring that gives about double the sealing surface, and seem to work the best. The 1s on the last manifold I tore down were wore to the same diameter as the poppet and would fall thru the hole. It was a 1992 rebuilt manifold and...

New O rings are used, Some are Cat most are Viton Fluoroelastomer with Durometer hardness of A75. and meet ASTM D2000/SAE J200 and MIL-R-83248C I guess I must be a lucky redneck :whistle:

Here is the pic of the part #s

Here is the installed unit and a picture of the Parker part #s The Regulator / filter unit is PN P3NEA96GSMBNM and the oil mister is P3NLA96LSN

I used a Parker unit Primarly because of the temp range its good to 175 degrees ( although its not near anything hot ) Also there NEMA 14 weather proof and have removable tamper proof knobs. So in plain english they were darn expensive. I'll get the part #s posted. I went with a 3/4 pipe size...

You are indeed correct There are a ton of O rings, poppet valves, and springs in the contoller group ! But I'm 3 for 3 on rebuilding them myself. A good amount of hours work! but if its all flat and clean and assembled correctly they work as good as new after testing them ;-) I Would not...