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Doing all the preventative stuff to me 2005 F-250. When taking of the HPOP cover i had a miscue. I could not get the cover off. Never having one off before i wasnt sure how hard to pry ,pull or where. I found a VIDEO on you tube from ford master tech where he inserted a socket with extension into the port where the turbo drain comes in. It just popped right up in his video. Well it didnt quite work out that way for me. You can see it cracked. Seeing that there is only an o-ring holding this in. Is this drain tube under high pressure? Can this be welded and saved? The tube still fits in there tight. Or dose it even need welded if its not under pressure. Not sure why the tube just plugs into the cavity and no bolts holding it. If i can figure out how to attach an image....
What you describe is not very uncommon at all. What I usually do in those instances where the cover is stubbornly attached, is to spray liberal amounts of PB Blaster, WD 40 or penetrating fluid all the way around the circumference of the pump cover to pump. Let it soak, and pry up GENTLY in a wiggling motion until the pump cover breaks free of the pump.
But in answer to your question, no the oil is not under a lot of pressure as it exits the turbo, but I would still be more comfortable with replacing the cover, but that's just me.
I will admit to have cracked that cover exactly the way it is illustrated. For this exact reason, I will sometimes quote the cost of a new cover if I suspect or foresee an issue with removal.
Been there, done that. The crack looks to end close to where the o-ring seals. If it were mine, I would try it. If it does leak, it isn't too hard to replace. If it doesn't, you are good to go!
What is the cost of a new cover? I kinda look at it like might be worth it to replace it and not worry about it leaking and having to do the work again.
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