Oh boy! The front seal has clips that holds the seal for one thing, and another is the drain back hole is too small, that it create's too much preassure pushing the seal out kaya nag pop and blowing the all the fluid right pass to the seal. You must mention this to your mechanic concerning this problem. If they are good (mechanic) w/ a right tools they could drill out the return hole to a bigger size (compare the return hole in your original tranny) glue the seal in and hammer the retainer in place to help hold in it.
I dont know where the return hole is to be drilled out in order to relieve the pressure behind the seal, you or they must have to search the answer or perhaps they know if they are specialized in tranny. Im sorry I cannot help you this. I believe instructions on how to do this is comes with the rebuilt kit and in a shift kit.
Believe it or not (not the T.V series), but a bad throttle position sensor can also cause this problem. If the ECM thinks the throttle is push down more than it actually is, then it is a problem this will cause the a high preassure situation. Your mechanics must remember some throttle position must be calibrated upon installation.
You dont have too, but recommended...
You know, I know, your mechanics know, we all know that wear on the torque converter hub may be too much, well some said, they said, I said and just dont know yet what you said that always replace torque converter if sign of aging is present. May cost additional hole in your pocket but its better than pull it back for a leak and extra grand not to mention another labor.
Lets go to double checking....
Did you replace the seal around the pump housing?
Does the torque converter have a pin hole in it?
Concluded......
Too much pressure almost always will push the seal out of the housing before it will leaks where the spring loaded lips are on the seal.
Good luck....... Wheeeeew!!!

