defender TD5 turbo actuator stuck

[mattmac]

I went to test my defender TD5 turbo actuator rod was operating correctly after reading various forums- couldn't get it to move with vice-grips -disconnected at turbo end and spray and sprayed some WD40 into turbo shaft which was moving freely but can't get movement at actuator end -do i spray WD40 into actuator end to try free it up or just replace actuator.

[Dorian]

I went to test my defender TD5 turbo actuator rod was operating correctly after reading various forums- couldn't get it to move with vice-grips -disconnected at turbo end and spray and sprayed some WD40 into turbo shaft which was moving freely but can't get movement at actuator end -do i spray WD40 into actuator end to try free it up or just replace actuator.

I'd replace the actuator, but they do take a fair bit of force to move. They are just a diaphragm and spring, so if it's not moving then it's one of these that is most likely broken. If you have got compressed air then you can check it with that, but be gentle it's only designed to go up to 40psi or so.
With the waste gate, check that it still rotates when you press it in the direction of the shaft. I had a heap of problems with overboost / limp mode (D2), the waste gate seemed fine when I checked it. Eventually found that it had a lot of float on the shaft and the gate would stick open when the shaft floated towards the engine but only when hot. My solution (tip from British Offroad) was the wear the "sticky bit" away by running it back and forth with a pair of multi grips, worked a treat for me.

Cheers Glen

[mattmac]

I just replaced the actuator but new one has threads starting further up rod so can't adjust to same number of threads as old one-what's the best way to adjust rod length?
I'd replace the actuator, but they do take a fair bit of force to move. They are just a diaphragm and spring, so if it's not moving then it's one of these that is most likely broken. If you have got compressed air then you can check it with that, but be gentle it's only designed to go up to 40psi or so.
With the waste gate, check that it still rotates when you press it in the direction of the shaft. I had a heap of problems with overboost / limp mode (D2), the waste gate seemed fine when I checked it. Eventually found that it had a lot of float on the shaft and the gate would stick open when the shaft floated towards the engine but only when hot. My solution (tip from British Offroad) was the wear the "sticky bit" away by running it back and forth with a pair of multi grips, worked a treat for me.

Cheers Glen

[Dorian]

Before I found that my problem was the waste gate I'd mucked around with the actuator so much that I didn't really have a good start point. I had a nanacom which made it fairly easy, take it for a drive and look at the boost when your at full noise and adjust from there, start low. If I didn't have a nanacom, then I'd be adjusting the boost up until I got an overboost at full noise and then backing it off a bit. For a start position I'd try to take a measurement from say the mounting bracket for the actuator to the eye of the waste gate lever and repeat it with the new one and then go a bit lower. From memory the max boost of the Disco TD5 was 2.5 atm or 36 PSI, some one pls correct me if i'm wrong.
Others might have a better suggestion though.

Cheers Glen