Nigelw Posted June 11, 2015 Share Posted June 11, 2015 Had this a while back, over a year ago for sure, but the wastegate spindle seems to be seized solid, performance seemed a bit lacklustre these last few weeks but put it down to barely being driven apart from groceries but a bit of a fettle with plumbing in the boost gauge to see whats going on showed almost nothing happening at all. done the usual, liberal dousing in wd40 slow steady applications of man sized pressure and zip all happening. whats next? Quote Link to comment Share on other sites More sharing options...
reb78 Posted June 11, 2015 Share Posted June 11, 2015 I've heard of folks replacing the brass 'bush' (?) that the arm runs into the turbo through on TD5 turbos. Could that have worn on yours? Quote Link to comment Share on other sites More sharing options...
Tanuki Posted June 11, 2015 Share Posted June 11, 2015 This happened on my TD5: depending on whether the wastegate stuck open or closed, it gave an engine which was spectacularly lethargic at all times, or went like the clappers until the MAP-sensor detected prolonged overboost and switched to limp-home fuelling (when it became lethargic again). The answer is to disconnect the pressure-actuator rod from the balljoint on the wastegate-actuator arm, and give the actuator arm a good wiggle, or a tap with a hammer to free it off. Don't use any lubricant - if you do, the copious amounts of heat from the exhaust will carbonise the lubricant and make the thing even more sticky! It's designed to operate as a 'dry' bearing. Quote Link to comment Share on other sites More sharing options...
Nigelw Posted June 11, 2015 Author Share Posted June 11, 2015 Good question Richard, if I can free it up this time then perhaps get it reconditioned locally, it could probably benefit from new seals, might slow up the oil consumption anyhow? Still bathing in WD40 for now, gonna pop the clip and actuator arm off and give it a wriggle again tonight after work. Quote Link to comment Share on other sites More sharing options...
Bowie69 Posted June 11, 2015 Share Posted June 11, 2015 After bathing in WD, clean it off with brake cleaner to remove the oily residue, to stop it carbonising again, as above Quote Link to comment Share on other sites More sharing options...
JeffR Posted June 11, 2015 Share Posted June 11, 2015 Took me the best part of a day to free up the wastegate with the manifold on a bench, used a mix of diesel thinned down with petrol to get it to start moving, then moved on to a thin 3 in 1 type oil. Once it was free (still got the blisters) I used a molybdenum based oil mix (actually Molyslip and 20w40 mix) to lubricate it. However 6 months on it's starting to seize again. Quote Link to comment Share on other sites More sharing options...
Nigelw Posted June 12, 2015 Author Share Posted June 12, 2015 Does anyone know how it all comes apart before I immobilize myself removing the turbo? It is not shifting one bit at the mo, guessing I ought to pull the turbo an try it on the bench as trying with reasonable force feels more like I am going to shear the arm off the spindle now that would be a slight disaster! Was wondering whether complete removal was an option and just run fully charged all the time? Quote Link to comment Share on other sites More sharing options...
Nigelw Posted June 12, 2015 Author Share Posted June 12, 2015 Well, good and bad news! Good news, I no longer have a seized wastegate lever. Bad news, pictures paint a thousand words. Quote Link to comment Share on other sites More sharing options...
JeffR Posted June 12, 2015 Share Posted June 12, 2015 Mine was seized, but not that seized.. Quote Link to comment Share on other sites More sharing options...
RedLineMike Posted June 12, 2015 Share Posted June 12, 2015 We're you pushing or pulling Quote Link to comment Share on other sites More sharing options...
Nigelw Posted June 12, 2015 Author Share Posted June 12, 2015 It was more of a rocking motion Mike, it didn't move in any direction then off it popped. Quote Link to comment Share on other sites More sharing options...
Nigelw Posted June 13, 2015 Author Share Posted June 13, 2015 Current options, used turbo of unknown origins and condition off Marktplaats €225. Try and get it rebuilt but at an unknown cost with this problem, or pop the elbow off and try and close the flap up a bit to give some boost? Any other ideas? Quote Link to comment Share on other sites More sharing options...
reb78 Posted June 13, 2015 Share Posted June 13, 2015 What about a secondhand, even scrap one and transfer the waste gate portion over? Not got one in front of me, so I don't know of it's possible, but it'd allow you to keep the known good bits of yours? 250 euro sounds a lot. I'm sure secondhand disco turbos can be found for around £50 over here? Worth a search if you haven't already maybe? Quote Link to comment Share on other sites More sharing options...
Tanuki Posted June 13, 2015 Share Posted June 13, 2015 Well, good and bad news! Good news, I no longer have a seized wastegate lever. Bad news, pictures paint a thousand words. The phrase "Oh, DoublePlusUpBuggerage!" comes to mind, followed by an in-depth conversation with your credit-card. Quote Link to comment Share on other sites More sharing options...
Nigelw Posted June 13, 2015 Author Share Posted June 13, 2015 What about a secondhand, even scrap one and transfer the waste gate portion over? Not got one in front of me, so I don't know of it's possible, but it'd allow you to keep the known good bits of yours? 250 euro sounds a lot. I'm sure secondhand disco turbos can be found for around £50 over here? Worth a search if you haven't already maybe? On the bay they are trading at around £50/£75, but silly money for S/H stuff here, was thinking to suffer the asthmatic drive until Wednesday and pop it off and see if I could work some bush magic with my welder and some spare hardox round bar I have under the bench, maybe even turn it down a couple thou to stop it happening again? I was how ever distracted by a couple of threads bleating on about VNTs, got a breakers local who get a lot of Sprinters in, thinking cash is king and maybe a couple €50s in my pocket could yield an interesting project? Drove to Albert Heign today for groceries, by golly is it even more noticeable the lack of power Quote Link to comment Share on other sites More sharing options...
Boydie Posted June 14, 2015 Share Posted June 14, 2015 I would be pulling it part and replacing the existing broken shaft with something like 302 Stainless Steel. It shouldn't be too hard - other than machining the new shaft. I would look at filing out the existing lever to a square and having the end of the shaft also square - to fit inside the square of the lever - and drilled and tapped at the end to take a retaining bolt. Quote Link to comment Share on other sites More sharing options...
Nigelw Posted June 14, 2015 Author Share Posted June 14, 2015 It is coming off tonight after work, hopefully all studs in tact :? Quote Link to comment Share on other sites More sharing options...
Nigelw Posted June 14, 2015 Author Share Posted June 14, 2015 Only sheared one turbo to manifold stud, quit whilst ahead so still a chance of shearing off the other 3 but it is off after an hours faffing around! Quote Link to comment Share on other sites More sharing options...
duncmc Posted June 15, 2015 Share Posted June 15, 2015 Just remember to take ALL those rags out when you put it back together, and yes I forgot one...didn't do any harm luckily. Quote Link to comment Share on other sites More sharing options...
Nigelw Posted June 18, 2015 Author Share Posted June 18, 2015 Just remember to take ALL those rags out when you put it back together, and yes I forgot one...didn't do any harm luckily. Only harm done was to my bank balance Dunc as this is now case closed with the shiney new one Quote Link to comment Share on other sites More sharing options...
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