Removing oil return tubes - what am I doing wrong?
 

I'm replacing all 4, so I decided to start with the easiest one to access, rear passenger side. I got the vice grips out, expecting the tube to crush no problem. Maybe not quite like a beer can, but without too much problem. Almost 2 hours later I finally have it off. I had to dremel holes into it, hammer a screwdriver in, then finally ram a small pry bar in there in order to get enough of a hole that I could bend it enough to get it out.

Do I just need bigger vice grips? Mine are the regular ones, probably 10" long.

http://forums.pelicanparts.com/uploa...1358107055.jpg

The crushability you expected would have been if the oil return tubes you have in your pic were OEM originals. What you have there are replacement items that are double-thick where they slide, so are going to give you more trouble. The clip give this away.

So do I have to dremel them all?

No, remove the circlip and the lower (engine case side) slides over the upper. You only need new seals unless the tubes are damaged (well, you do need at least one new tube).

You can reverse the process by removing the clip and try compressing them back into each other, just the reverse of the process you will shortly be going through to replace them.

Make sense? Clean them up to allow the tubes to smoothly contract into one another by grabbing the smaller OD item and pushing it into the larger OD item. BF lockjaws should do it.

No, remove the circlip and the tubes should compress so you can remove them. Its what the aftermarket replacement tubes are designed to do.

Ok, that sounds much simpler! I'm replacing all the tubes and seals, so not worried about destroying the old seals.

If the remaining three tubes are aftermarket type, replace just the old o-ring end seals with new. The one new tube will be fitted with new seals. Don't pry off or remove the circlip from the tubes. Just open it up lifting it out of its grooved seat using a circlip pliers, then slide it down the tube out of the way. The purpose of the circlip is to firmly lock the tubes into the engine. Once circlips are opened and out of the way, push the smaller I.D. tube into the larger I.D. tube and remove it from engine. Reverse this process to install. Remember, the reopened circlip must be replaced back into its locking groove.

Also be sure to liberally grease the new O ring seals with silicone grease! Install will be MUCH easier.

I used some left over grease from sway bar bushings.
You can also use silicon faucet washer grease.

Definitely BF pair of Chanel Locks. Tape over the jaws for some protection.