1. What is the height of the hy-tran in the casting cavity the pump is located in?
Same as the transmission level. Less if headed up hill, more if headed down hill.
2. Why is it lower than the o-rings we're talking about?
It takes energy to squeeze the oil out of the gears as they mesh. The oil level is a compromise between getting enough splash lubrication and heat. The higher the oil level, the more heat is introduced into the oil as the gears mesh.
3. How can it suck air there anyways unless it's vented to atmosphere?
The pump cavity is vented to atmosphere while the suction piping is not. You could be pulling air past the shaft seal or any of the suction piping joints. With a restricted suction (plugged filter/bypass) the pump cavitates which ineffect, vaporizes the oil into small bubbles.
If you think it is a suction problem, over fill the transmission and ensure that the oil level is above all the suction piping. If it starts working, suction piping somewhere, pump shaft seal, or the filter cavity is allowing air in.
If it still does not work, plugged suction piping, plugged filter and bypass, or bad pump.
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