Oil Return Tube Replacement - Mission Acomplished

[Targa Me]

Hello Everyone, I replaced my oil return tubes (left side) yesterday; here's how it went.

Subject car: 1984 Carrera with a stock 3.2 and 216k miles on the engine.

The front left tube was leaking the most leaving a nasty puddle of oil. When I first took a look underneath the car, the left side tubes look like they're impossible to remove without removing the heat exchanger first. And with 216k on the engine those HE nuts look like they are one with the threaded stud and would certainly snap off.

After reading several threads on the return tubes it was determined that the left side tubes can be removed and replaced without removing the HE, so I took a deep breath proceeded forward.

First I drove the a$$ end of the car up on ramps and drained the crank case of oil.

The front left was a stock tube and was easily crushed with a pair of channel lock pliers. The rear left had been replaced once before (by a PO) and was an extending or collapsible tube. Removing the tubes took about 10 minutes.

I tried to clean out the bore where the tubes get inserted, the front was not so easy...there's not much room to get my fingers in there, but I did the best I could.

While at the work bench I placed the o-rings (green) on the new tubes and then tried to slide the 2 halves (of the tubes) together...it was damn near impossible. I sprayed some Liquid Silicone lube on the o-ring and it was easier but still way too difficult considering that while trying to spread the tubes I would be underneath the car with very little room to work with. I took a few minutes off and revisited the PP threads for tube replacement. I ran across a thread where John Walker stated you must use Silicone Grease on the o-rings to slide the tubes.
(Thanks John)

So after buying some Silicone Grease I reattemped working with the tubes. I guess miricales do happen, the 2 halves slid on so much easier. Still required some effort, but it was noticibly better.

Getting the front left tube in place completely took about an hour and a lot of patience. What help me was spreading the tube on the bench to the point it was almost the exact length between the head and the crank case. (7-3/4 inches or a little more.)

After inserting one end of the tube and then trying to hold it in place while trying to extend it to get the other side in was frustrating but after several attempt I finally got it.

After struggling with the front tube for an hour, the rear tube was a piece of cake and I got that tube in place in about 10 minutes.

I replace the oil I drained from the case and fired up the engine... NO LEAKS ! Mission accomplished. I patted myself on the back and opened up an ice cold New Castle.

In the photos you'll see a pry bar looking thing with a hook at the end. I have a set of 4 of these I bought at Harbor Frt some time ago. They're made of a cheap metal and I wouldn't use them for any serious prying but for this job they were perfect.

Other than the pry bars, this job was completed with simple hand tools, nothing special.
Oh, one more thing, the idea of using hose clamps on the tube to pry against is a great idea...thanks to the guy that thought of that.
This job took me about 4 hours to complete.

[KNS]

Great work! That's about the same experience I had, Syl-Glide and hose clamps do the trick. You then go to the right side tubes and they're laughably easy.

[Neel]

Congrats for a job well done!! The search button is a wonderful tool.. Lots of good information out there!! That job, as are some others, is a PITA, but very doable at home with some basic tools and patience!!

[McLovin]

Nice work, but wow, that job looks like it was a half a decade or so overdue!

[pete3799]

Good job.....but where is all the rest of the oil coming from?

[RSM-M491]

Nice job, may I ask where you got your ramps? They look higher than the ones I have seen around here. Been looking to buy a set. How hard is it to back the car on to them?

Thanks!

[Targa Me]

Originally Posted by RSM-M491

Nice job, may I ask where you got your ramps? They look higher than the ones I have seen around here. Been looking to buy a set. How hard is it to back the car on to them?

Thanks!

I bought the ramps at the local auto store, pepboys, I think. Not a bad deal for 30 bucks.
Its not hard getting the car on them....just drive it up.

[shrtshck]

You can do the right side return tubes without removing the heat exchangers. I did all four on my 87 using the same equipment, car on ramps and me on my back. First spend some time under the engine with a couple cans of degreaser and small brushes. Remove as much grime as possible before removing the old tubes.
Review the threads on installing the expandable return tubes, placing gear clamps on each end of the tube will provide someplace to get a screwdriver / bar onto in-order to drive the tube seals into the engine.
After doing the left side you already know to expand them as much as possible first.

[DRACO A5OG]

Outstanding! Congrats Brother