So I got a rebuild kit from G-pop shop. I'm at the part where you lube up and press the shaft back in. The piston seal got caught between the shaft and CHRA. I pull it out and there is a nick in the shaft and a burr in the CHRA. The piston seal is bent and useless now.

:crying emoticon:

What did I do wrong?

The nick in the shaft is small and not really noticeable. The burr in the CHRA was cleaned up with a razor blade. Both should be ok now.

I swapped the old piston seal back on the shaft and attempted to push it in. Since I'm a little gun shy after last time it now sits unassembled while I wait for answers.

 

are you talking about the rear seal? just dont force it, wiggle the wheel around and with a little bit of pressure it should pop right in. use oil lube. try not to stretch the seal out too much when installing too

 

Yeah sorry I should have been more specific. It's just a stock S5 turbo with just the one rear piston seal.

I noticed the new seal that came in the kit was more flexible as I was installing it. I hope I didn't stretch it more than needed to get it on the shaft. Hmm, maybe I did.

But I also noticed the old seal is of a harder material and less prone to go out of shape from install/removal.

How bad would it be to reuse the old piston seal?

By the way this turbo smoked. Could it be caused by the piston seal?

Actually now that I think about it, the smoking was due to the looseness of the journal bearings and the 270 degree bearing parts. The piston seal was probably ok but couldn't keep up with the wobbly shaft. As it sits with just the new journal bearings installed, it feels a lot tighter. I'm thinking I could get away with leaving the stock piston seal on there for a little while. I gotta get the turbo back together like right now is the reason for the rush, otherwise I'd order a replacement from G-pop shop and wait for the next few days. I've just never rebuilt a turbo before so I figured I'd ask.

 

Update. I put the stock one back on and tried it. It went in as easily as they do on the rebuild videos you see on youtube. I'm like double you tee eff? That's all there is to it? Then what was wrong with the aftermarket one? Why didn't it want to go in at all?

I looked at the gap of both. They're both the same so no I didn't accidentally stretch the aftermarket one during assembly.

I measured thicknesses of both with a digital caliper. The OEM was thicker in every dimension. Sold! So I put it back on like they show on the youtube videos. Lubed it up and popped it in.

The turbo is back together and in the car. Next up down pipe connection to the center section.

Oh and the shaft play is a lot less now. Feels kinda newer than it did.

 

as long as it is a T3 or T4 piston ring, it should fit. not sure if the "big" shaft piston rings are different. you may just have to order a new one and make sure you dont stretch it out.

turbocharged.com sells the individual parts, cheaper than getting a whole rebuild kit. I usually just order the piston rings, thrust and journal bearings, and i think its about $40