Need Help 1992 300D Turbo Failure
 

2 days ago I had the turbo on my 300D 2.5 Turbo fail. It coated the intake manifold in oil and won't produce any boost.

From what I have read,that turbo is a Garrett TB2535 and the Garrett part number is 465445-2 or 465445-0002. I think that the turbo is intact enough to rebuild, but I can't seem to find any rebuild kits for this turbo. I was told that I might be able to use a T25 rebuild kit, but I'm not sure how true that is. Anyone know how to go about rebuilding this turbo?

Thanks in advance!

check your pm's

Try to find a local turbo diesel repair shop to help you.

Did you try mercedes source he advertises a few.

I think the difference between this and the earlier T25, other than the wastegate, is the exhaust side seal. The t25 had a carbon seal. I think this one has a dynamic seal.

The reason you get leak is that the capsule builds carbon deposits over time. If you don't get it completely reamed out, you'll have trouble again. Try G-Pop Shop for parts, rebuilds, and advice:

G-Pop Shop

Are you sure its failed? Turbo's don't fail unless the turbine doesnt spin or the fins are worn. Are you sure its not the P2 flap?

I have to ask - what is the "P2 flap"?

The common name for that is "waste gate".

On the 1992 that is controlled by the EDS box and a vacuum transducer. The flow is maifold pressure -> MAP sensor -> EDS controller -> vacuum transducer -> vacuum actuator -> waste gate.

There is a mod thread out there for converting the waste gate actuator to a simple pressure type. Mainfold pressure -> pressure actuator -> waste gate. Hmm which one has less things that can go wrong???

Thanks for the info jay_bob. Using this thread as a guide I did that to my OM602 in 2012. In fact pictures of the swap are at the bottom of this page.

Thanks for all of the quick replies!
 

The turbo is definitely dead. When I took it off last night I found that the exhaust side turbine was just floating around inside of the housing. The turbine is destroyed, it appears that it fell off of the shaft. From what I can see with the housings still on, the whole shaft is still there.

I've been talking to a sales rep at Pure Turbos and he said that I'll need a new cartridge most likely, since when a turbine comes off of the shaft it severely unbalances the turbo and begins to oval all of the internals. He's trying to track down a new cartridge for me and I hope to hear back from him tomorrow.

I'll also check out ************ and see what he has.

Has anyone else ever had to rebuild or replace one of these turbochargers before?

When I rebuilt the head on my 190DT, I decided that I should also rebuild the turbo, which had 310K miles on it. Searching around, I found a turbo from a 300D 3.5 that had been "recently rebuilt". Put it on the car. Now 20K miles later, it's hemorrhaging oil, like yours. So I sent my old one off to be rebuilt, but it's taken some time because it needed a new pressure wheel. As soon as it comes back, I'll have a spare 300D turbo that leaks oil, but who knows, it may be rebuildable.

I think this is much more common that people suspect. The 300D turbo is working well, just spraying oil into my intake. The only reason I caught it is that there was oil blowing out the manifold seals.

Luckily it was only the exhaust side! You will certainly want to have a rebuild professionally balanced. Might just be better off finding a quality used one at car-part.com.

I'm glad that it was just the exhaust side otherwise that would have been catastrophic.

The ones on car-part.com right now are expensive or will have to be shipped to me and I think still too pricey for not being able to inspect it in person before buying. Unless I can get a used turbo really cheap I'm just going to have Pure Turbo try to get me a new cartridge. The rep told me that if he can't find one, then they can get the parts and build me a custom one.

I'm going to take the turbo apart tonight and see what the condition of the center housing is. I'll take pictures and report back.

I am confused by some of the termanology.

The Turbine Wheel is the one that gets turned by the Exhasust Gasses coming out of the exhauts Manifold.

The Compressor Wheel is made of Aluminum and is on the Intake Side of the Turbo Charger.

The Exhaust Gasses push the Turbine inwards towards the Compressor end of the Turbo and that eventuall wears out the Trust Bearing and at the same time Thrust Bearing wear moves the Compressor Wheel closer and closer to the Turbo Intake Housing and if it gets bad enough the Copressor Wheel rubs on the Turbo Intake Housing.

When the Bearings in the Turbo wear the side play increases but from what I have been reading most of the failures seem to be from the Thrust Bearing Wear.

The Turbo 617s have Turbos that use Dynamic/Piston Ring type Seals on the Turbine end and the Compressor ends.
The later Modes eventurally switched to one of 2 types of Carbon Seals on the Compressor end. As far as I know the Turbing Ends always have the Dynamic Piston Rig type Seals.

When you read the rebuild turbo threads no one is measuering the Bearing Bores, Turbine Shaft Journals or the wear in the Ring groove on the Turbine Shafts.

That means onece in a while someone fix does not work as they expected because replacing the Bearings with the stock size and replaceing the Seals is not an entire rebuild.

Haven't pulled my turbo apart yet because I was thinking that I might just try to find someone locally who can rebuild it. The guy at Pure Turbo still hasn't found any parts so I'm becoming skeptical of the information he has provided me.

So, is it true that the center housing or cartridge of my turbo is truly ruined? Or is it possible to rebuild it if the shaft is replaced and larger bearings are put in as opposed to the stock bearings?

I don't have any experience with rebuilding a turbo, so I'm not sure if this is a dumb question or if that rep at Pure Turbo fed me a line of B.S. about how my center housing is completely useless.