Oil Return Tube Leak

[hypo]

Has anyone else had issues with multiple turbo oil return tubes leaking? I've seen a few reports of problems

I first noticed fresh oil covering the passenger side of my engine at around my 25k oil change. I don't know how long it was leaking for because I had been letting the dealer do oil changes up until this point. The dealer dyed the oil, confirmed it was the oil return tube, and replaced the part under warranty.

At 30k, I crawled under my truck to find more fresh oil on the side of the engine. Not trusting the first dealer anymore, I took my truck to a different dealer. The tech dyed the oil again, confirmed the oil return tube leak, and wrote that they cleaned the area and bolt holes thoroughly to ensure a good seal this time.

Surely that would have solved the issue, right? Wrong. Today, at my 35k oil change, there was even more oil than the first two times.

All 3 have been a slow leak, so there haven't been any oil spots on the ground to alert me that I sprung a new leak. I'm also questioning whether I happened to be the first one to discover that I sprung a leak after 20k, or if the lube techs at the dealer had just not been saying anything. It's possible that the leak developed after 20k, but seems less likely to me now that the third tube is leaking.

Sponsored

 

[FerdRanger]

I had mine replaced about a month ago after noticing substantial oil spots after an oil change. Service manager suggested it might be typical oil change droppings, but turned out to be the return tube

haven’t noticed additional drips…. guess I’ll keep the possibility of this happening again in mind.

I was relieved it wasn’t the main seal

 

[airline tech]

NOTICE: Do not use a metal brush, damage to sealing area will result in leaks.

NOTE: The oil return tube must be fully seated prior to fastener rundown.
Carefully use a nylon brush to remove the old O-ring residue, use brake cleaner to rinse the O-ring residue out of the turbocharger tube O-ring bore. Inspect the area for deep scratches and gouges. Install new components if needed.

Install the turbocharger oil return tube, then install and tighten the turbocharger oil return tube bolts.
Torque: 97 lb.in (11 Nm)

I suspect an issue with the mating surface (Block Side) May not be flat - if it's been replaced (2x) and still leaking, ensure NO scratches or gouges from a wire brush or scrapper
or they are not torquing to specs.

Might have to add some RTV to this as an alternative.

 

[hypo]

The dealer "cleaned mating surface and bolt holes" and replaced the part again. Not exactly confidence inspiring, but it's all covered by warranty so far. It hasn't leaked yet after a couple hundred miles this week.

Thanks for the tips. I'll keep that in mind if/when the leak pops up again.

 

[airline tech]

Cool - hopefully it will remain leak free.
I am wondering if the previous replacements they were not torquing it down evenly.
One side fully torqued before the other side.
So even though the manual does not state to do so, snug it up - Both Bolts, then 1/2 the Torque Spec on each bolt, then 2nd round full torque spec.
What may have happened - full torque on (1) bolt prevented equal torque on bolt (2) and the mating surface was lopsided allowing oil to push past the O-ring

 

[hypo]

Yeah, would make sense. Thanks again!

 

[Frenchy]

You sure it's the tube and not the gasket? Had to deal with this on a Forklift and it was just the gasket. Of course it may be a bit of a pain to fix on the Ranger

 

[airline tech]

If I recall correctly, the T-Shoot procedure for leaks here - replace the tube assembly, since this is a warranty repair- that’s what the dealer is doing.
So tube replacement also replaces the O-Ring (Gasket)
With 2 previous tube replacements, something is not right - either mating surface or install process.
Yes the the O-Ring is leaking but why Is it a continued leak? Is what needs to be determined.

Sponsored