Oil Return Tubes

mgbruno · 01-16-2007, 03:56 AM

Greetings all,
I introduced myself a while back and take a look at this forum almost every day but rarely have valuable insight... so I just keep quiet. I've got an 84 911 cab and did my first real repair over the long weekend - replace oil return tubes - and thought I'd share a few insights that I don't think have been covered completely yet. (Maybe they have, and its just my cluelessness finding the info). 1st off, I pretty much removed my entire exhaust system (heat exchangers etc) before I began the repair. This really let me get at the tubes easily. Course I didn't anticipate having to replace the exhaust gaskets, but after I removed and looked at the things - yep, I'm gonna have to do this. Next, of course i bought the expandable tubes that are sold by our host and had an incredibly hard time installing the 1st one. The circlip is a bear to get on without two people and "circlip" pliers. Didn't know they make them but my neighbor had a pair and they work great. Then, the tube fits togeather very tightly after installing the seals. I'm a Marine and pretty much used all my strength to get the darn thing togeather - so it definately is a very tight fit. Then I oiled the end seal and installed it in the car. But expanding the tubes again! Aiyyyyy, how on earth do you do it??? Well, again, I tried pulling the tubes apart as hard as I could but no luck. I tried everything - vice grips, hose clamps, etc, etc. There is no way I can see anyone being able to "muscle" those tubes apart. So after sweating on one tube pretty much all day the dumb grunt began to think - "its gotta be brains and not brawn" So, here's a simple trick I thought of! Works like a charm! I put one hose clamp on the female side of the return tube. Then I put the other hose clamp on the male end. I put the clamps as close togeather as I could. (Oh, BTW, before I did this, I installed one end of the tube into the car). Anyway, once I got the two clamps nice and tight, I just pried them apart with a long screw driver. Of course, the clamps didn't slide - the tubes did! Then you just simply loosen one clamp slightly and slide it close to the other one, tighten, and then pry the tubes apart this way. So, thats it. Its a matter of leverage and not pure muscle. I'm sure some other smart Pelican has found another way to get the tubes apart, but this ended up being my solution. It works like a charm, doesn't harm the tube, and is pretty straightforward and simple. Hope this helps a fellow Pelican in need.

Semper Fi,
Mike

Dan in Pasadena · Dan in Pasadena's Garage

Quote:

Originally posted by mgbruno
...I'm a Marine and pretty much used all my strength to get the darn thing togeather - so it definately is a very tight fit.

Are Marines stronger than all us non-Marines?

Kidding. I had already read in several threads about using hose clamps on these things but I always assumed you'd use one to push on. Using two and a screwdriver as a prybar sounds like a great idea. Time to transfer to Army Intelligence? Or is that an oxymoron?

Congrats on your success. Pictures?

mgbruno · 01-16-2007, 04:23 AM

Hi Dan,
We like to think we're stronger - but judging from performance prying those tubes apart.... I'm not so sure anymore! Yep, I too had read about using the clamps - but like you assumed it was meant to push one side in. Then when I thought I was going out of my mind, I came up with the idea about two plus screwdriver plus leverage. Concerning the pics - I asked my wife for her camera and she looked at me funny - laugh. Women will never understand!! I plan to pose some pics later. Before and after as well as the entire installation idea. My heat exchangers are filthy. Well, I took some oil and light steel wool to them. Wow!!! They look brand new! Also, the entire underside area where the tubes are - they were really leaking - so, I'm still going to degrease and clean. So, before and after pics to follow.

Dan in Pasadena · Dan in Pasadena's Garage

Quote:

Originally posted by mgbruno
... Then when I thought I was going out of my mind...

Oh, now I know were you messed up....you didn't choose your swear words carfeully enough! Ordinarily I try to "watch my mouth", but in that situation I can cuss almost like, well... A MARINE!

No kidding, I'd almost swear that I HAVE sweared a few nuts off of bolts in my life!

Thanks for the morning laugh but I've been there and I know it isn't funny at the timne. I can just imagine being under the car with the old tubes crushed, BUSTING a gut trying to get the futhermucking #$^$%&% in there and thinking, "Now, what do I do?...can't drive it to a shop like this, sonava ^&%&*!

Usually in that case, my brain s l o w l y returns from wanting to kill something before starting to work again.

Rot 911 · 01-16-2007, 05:30 AM

Mike, glad you got the tubes on! However, in order to save yourself a bit of time on your next project you might want to do a search on here first. On the o-rings you should use a silicon lubricant which will help considerably on expanding the tubes.

Pelican also has a tech articles section which includes most of the usual maintenance tasks including replacing the oil return tubes. http://www.pelicanparts.com/911/911tech_articles.htm

Finally you might want to get Wayne's "101 Projects for Your 911" which will take you step by step through most of the common maintenance projects.

mgbruno · 01-16-2007, 05:36 AM

Hi Kurt,
Yep, I did look at the Tech article on replacing the tubes, and I've got the 101 projects book. Neither article ever described the expanding the tubes technique. Now, concerning the silicon lubricant - I never thought of that - though I considered it. I put oil everywhere and boy was it a tight fit. Thought - "what difference can silicon make over oil". Maybe I'll try the next time - laugh. Hopefully that won't be for a while though.