1984 300 SD, I'm planning a turbo rebuild.
 

I've read everything in the quick links but can't seem to find a step by step on removing, tearing down and reassembling a turbocharger.

I'd appreciate a link to the process if anyone can find one.

I have a 85 300 and I'm going to do almost the same thing as you with the exception of removing the turbo completely off the engine. I've purchased new seals and impeller and to carry it one step further a used complete turbo in case things (rusted bolts) cause any issues. Can't really post the "source" of my parts, but the kit does come with a step-by-step procedure. The impeller added about $100 to the kit and is not necessary to purchase. Good luck.

Try searching from google w/ "peachparts" in the search string. I recall at least one post w/ good photos.

I removed a turbo from my 1984, but not to rebuild, just for access for weld repairs on the car. I needed the square metal gasket for the turbo exhaust, and found it is a standard size which I bought cheap on ebay in better stainless. If I recall, size is "T4", but can't find my notes.

The 617s are t4 sized turbos indeed, idk if its a garret specific size name or not, when I replaced my w116s turbo it was a garret t4 kit.

Ill give you a tip, force has no place in a turbo. Thats how I ended up replacing mine.

The compressor housing has a tiny little piston ring type thing as the seal, I had fits getting it in right, so I smacked the housing with my fist thinking it needed to pop into place. Gouged the aluminum housing, leaked like a sieve.

Learned my $700 lesson there.

That works, but a cleaner approach is to use the Google advanced search structure and preface your preferred search with "site:peachparts.com" followed by a space and your search word or phrase.

In fact you can use "site:http://www.peachparts.com/shopforum/diesel-discussion/" to limit search results to just this specific forum.

This is so much better, I don't think I've used the forum's search function in years.

You can PM the OP.

Yep, he sure can.
 

I found these videos and would like some of you folks to review them for accuracy and detail. There are two parts to this exercise.

https://www.youtube.com/watch?v=I2CwBwrdnvA

https://www.youtube.com/watch?v=wqXe0ln7-WQ

As I previously stated I have the 84 300 SD and as far as I know the turbo is stock and hasn't been off the car. How will I identify it to find a matching rebuild kit?

Why are you rebuilding it?

300+K? Well, that and there are some leaks coming from that area which I intend to remedy. From what I've read here at 300+k there surely must be some oil going where it doesn't belong.

I've never rebuilt a turbo. That alone is enough for me but I'm believing that the car will be more dependable if all such systems are refreshed.

Is that justified?

Might be fun to rebuild. However on my 81SD I personally would not do it unless I was experiencing a problem. Some take a different approach. Neither is wrong.

x2


I've seen these cars with well north of 500k on them (the mythical 500k, or is it 1 million on CL? :D) and the turbos are still working perfectly fine. I doubt we'll see cars this heavily-engineered and built again.

The way I see it, if I wait until there's a problem then I'm late. I spent my entire life being managed by fate, it's my turn.

I have read rebuilding is not a problem,but you need to have it balanced.If it has a lot of play in the shaft do it,otherwise not needed.

I intend to check the shaft play before I tear it down. If it doesn't wiggle I'll proceed with caution. If it shows play I'll buy a shaft before I remove the until from the car.

I expect some drag on the shaft from buildup of exhaust and I know there's some oil coming from either a seal or the turbo to block gasket. This is as much about fixing an oil leak as anything but it seems to me that removing it from them engine is more than half the battle.

Not sure of the current pricing, but "G-Pop Shop" in Ark. rebuilds those in the $350 range and they have a great reputation. The kit and parts are probably north of $100, so probably worth the investment to get a shop. Should fit inside a USPS flat rate box, so $18 each way, so around $400. Just my .02 cents. Similar to buying a new MB vacuum pump vs. rebuilding one, $300-ish vs. $125-ish, but no headaches ...