Turbo Oil Return Line Seal? - CURRR....

[baudenfj]

I am trying to put in a new seal on the turbo oil return line on a 83 - 300 SD! I read quite a few posts and printed out the manual but STILL have problems.

Here is what I did to replace the seal:

- Taking out old seal was pretty easy since it was hard and crumbled.

- After the seal was out I could press the pipe further down which made it fairly easy to take to top pipe connecting to the turbo out.

- I put a hose clamp around the lower pipe a piece of wood against it and hammered it out in now time.

- I took the lower oil pan off to get all the particles out from the crumbled seal. I was surprised that in contrast to what is out on the forum I HAVE NO CHECK Valve at the bottom of the pipe.

- I inserted the new seal in the lower oil pan which I put half way up on the oil tube to avoid catching the o-ring with the upper lip of the grommet.

- Then I used a long C-Clamp to press it in. The c-clamp works great! I can get it in so it sits about 3/4 of an inch above the bottom surface of the oil upper oil pan.

- IF I PRESS IT IN FURTHER the seal is destroyed and the bottom part shears off.

- The way it is in now I can not get the top pipe in and I trying very hard. I can get the lower pipe inserted into the top one but I can not bend it back to be straight up. It seams that the lower oil pipe is sticking at least 1/2 and inch to much out.

- DO I MISS SOMETHING? DO I HAVE TO take the turbo off. IF I leave the seal off and insert it all the way down into the oil pan it goes together quite nicely! (almost too easy!)

ANY HELP APPRECIATED!