I just really have a soft spot for things that work.
I'm hearing ya dvst8r. It's not that I don't appreciate the help, but, I already have spent the $$ to make the back of the cummins look like a chevrolet. My mid plate and all would have to be changed in order to get back to chrysler.
I removed the tranny today and placed it on a pallet for shipping. I'm pretty sure I found the reason for the latest failure. When I unbolted the torque converter, I could slide it back a little over 1/4" before it bottomed out in the tranny. In earlier conversations with FTI, as long as I had between 1/8" and 3/16", I did not have to shim the converter. Well, to be honest, I looked at the clearance when I bolted in the tranny this time, but, did not check it as it has always been good before. I'm betting the notches in the converter slipped out of the pump when I came down on it and pushed the pump backwards. This would cause the pump to wear very quickly and not hold good pressure.
This converter has been cut apart twice since I first installed it. Originally, when the pump bottomed out in the bell, you couldn't spin the converter because it was hitting the bell. I did notice during the last install, the converter would spin freely when bottomed out. I'm not 100% sure this is my converter. I looked for identification numbers and couldn't find anything. I pulled a tape across the front and it still measures the same. The last stall let me get to 2500rpm and Gregg was supposed to loosen it up another 500. I could only get 2000rpm out of it this last time so it may be some other persons converter.
Regardless, I wouldn't feel right not giving FTI another go at it if they are willing. This time, the converter will be very loose.
On a brighter note, I did finally get my custom plates on.