So this is now my third time replacing those exquisitly designed plastic elbow fittings that seem to be the achilles heel on everyones 3800. Before I go throwing another set in to have the top one blow out again in another year or two I was wondering what the best method of prolonging the failure is.

I have read about replacing the o-rings on the replacement elbows to bigger ones and also just making sure they are lubed up well enough. I want to try and get all the best fixes on one thread so everyone can see this untill someone becomes a millionaire by partnering with a machine shop and making metal versions.

Any help is greatly appreciated!!

 

Are you using GM parts or the Dorman replacements?

 

I've used both, the GM ones do last a little bit longer but still have had the same problem after some time. I have been cleaning where the fitting plugs in each time I have replaced them to ensure a good fit.

 

I read earlier this year a LOT of people complain about the Dorman elbows (my that I put on last spring popped out on my car this summer first week I had the Monte on the road). I bit the bullet, put in GM ones.
But I have used Dorman on a couple other cars a couple years back.
You must make sure (and it sounds like you did) that ALL the plastic elbow came out (sometimes a ring is left in the intake, must be removed).

NOW, when you lube the elbow up, it does not take much. I use either plumbers lube or vaseline (both about the same) ONLY a thin coating (barely enough to look like it's on there) on the part of the elbow/o-ring FIRST going into the mating surface. If you put it ALL over or in large quantity, you run the risk of pressure easily sliding it back out. All the lube is for is to ensure the O-ring does not slide off (as I had that happen once too).

 

i bought mine from dealer,put a small amount of rtv sealant on each o ring before inserting no leaks so far.