Found a torn diaphragm on my '84 300td wagon and upon inspection I decided to repair and it was successful! I carefully removed diaphragm from pod stalk, cleaned off grease with solvent brush and mineral spirits and then carefully joined the two sides of the crack together with forceps and tape. I painted on black tool dip (stuff you dip tool handles in to rubberize -I have used this stuff for all kinds of weird repairs!) and then let cure for 4 hours. Vacuum is now amazing! Door lock flies up and down -previously, it would pull vacuum in the down position as the diaphragm folded back on itself and self sealed -when pushed up all vacuum lost as diaphragm crack bled off air. Note: Push diaphragm back on stalk carefully as diaphragm is still fairly delicate and use as synthetic grease on stalk and diaphragm lip to assist sealing capability. Hope this helps others -btw, new diaphragms may be purchased for 6.00 each from George Murphy at perfanalysis@comcast.net Good luck!

Was your actuator a VDO brand actuator? I notice that those, unlike the original Mercedes-Benz type and other brands have a crimp on the stalk that doesn't allow you to remove the holder and get at the diaphragm.

__________________
'81 MB 300SD, '82 MB 300D Turbo (sold/RIP), '04 Lincoln Town Car Ultimate

Sooner or later every car falls apart, ours does it later!
-German Narrator in a MB Promotion Film about the then brand new W123.

I repaired one of mine with bicycle inner tube patches. I put one on both sides of the diaphragm. It worked for about 6 months before it gave out again.

__________________

I've repaired a couple using wet-suit glue and a bit of rubber glove.
Steve

__________________
1980 300 TD

1997 Dodge Pickup/Cummins 5.9 12-valve