I started out to replace the o-rings and sleeve on the turbo oil return line on my 1981 300SD. I've done this many times, but never encounted the problem I found today.

First, I pushed the pipe down as far as it would go. When I started to get the sleeve up and out, it started to come apart. It was only 2 years old. The pipe would not come out. I tried removing the oil pan and pushing from below. No luck. I finally removed the air cleaner and the alternator and proceeded to dig the old sleeve out piece by piece.

My question is there anything I could have done differently to avoid this problem? I've got to do the same repair on my other 300SD and don't want a repeat.

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Tom Evans
69 280SE 91K (wish I still had it)
73 220D 98K
78 300D 134K
78 300D 185K
81 300SD 301K (still have)
82 300SD 321K (still have)
84 300D 268K
84 6.2 Diesel GMC Suburban 225K (a whole different story!)

Somewhere in my thread is a pic of me using a socket to tap the Tube and Grommet out from below with the Oil Pan removed. But, I believe that was after I first pulled off the upper part of the tube.
Turbo Drain and Blow-by Drain Seal Replacement; Mein Kampf
Turbo Drain and Blow-by Drain Seal Replacement; Mein Kampf

I think I have read in other threads where members have had to dig the pieces of the Grommet out. I may have more to do with the condition of the Grommet than the method.

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84 300D, 82 Volvo 244Gl Diesel

Diesel 911, I tried your method, using a socket to push the grommet out. It simply wouldn't move. The lip of the grommet held the tube in place. That's when I went to the dig-it-out method. I think you are right - it has to do with the condition of the grommet. What's scary is that the other car I need to do the same repair has a much older grommet.

I see where you have a 123 body. I have a 126 which means I don't have the A/C hose in the way. My son has a 123 and I replaced the Grommet and o-rings when I had the A/C hose out. You are a brave person to attempt this work with the A/C hose in place!

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Tom Evans
69 280SE 91K (wish I still had it)
73 220D 98K
78 300D 134K
78 300D 185K
81 300SD 301K (still have)
82 300SD 321K (still have)
84 300D 268K
84 6.2 Diesel GMC Suburban 225K (a whole different story!)

I did loosen where the A/C hose mount where it attaches to the Block and that gave a little extra room.
But, I have noticed from some of the other members pictures. Evidently all of the 123 A/C hoses do not run exactly on the same path.
So some may allow more room than others.

what I had the most trouble with was getting the Tube into positon to pull the upper half out.

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84 300D, 82 Volvo 244Gl Diesel

I got to thinking about what you said in your first post. I used a 16 MM shallow socket and a 3" extension to try to drive the tube out of the upper oil pan. You used a deep socket. I'll bet the deep socket would deliver more force that the shallow socket and extension.

I've got one more car to do this repair on. I'll keep the deep extension socket handy. Maybe I'll get lucky and the sleeve will pop up like it should.

__________________
Tom Evans
69 280SE 91K (wish I still had it)
73 220D 98K
78 300D 134K
78 300D 185K
81 300SD 301K (still have)
82 300SD 321K (still have)
84 300D 268K
84 6.2 Diesel GMC Suburban 225K (a whole different story!)

I do not remember all the details but I think I used a 2 Pound Hammer. With the 2 pound Hammer you do not have to swing fast or even hard and it will not bounce back like a lighter hammer will.
I also think that ounce I got it moving I had to use an extension to push it the rest of the way out; as I do not recall hitting my Fingers with the Hammer.

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84 300D, 82 Volvo 244Gl Diesel