Everyone,

Pulled in my wife's '94 940 Turbo to debug an oil leak leaving reasonable size puddles in my street and found the oil breather box split open on the top of the small round section towards the front of the engine. With the engine running I could see oil bubbling out of the crack. The breather box, flame trap, and hoses were replaced about 1 year ago so all the parts are new (breather box was aftermarket). I also pulled the hoses and the flame trap was clear with only a little oil in it.

What I am trying to do now is determine the cause of this split before I put in a new box. Any ideas on what might be causing the issue? Ideas I had:

1.) Low compression or broken piston rings in one cylinder causing excess crankcase pressure and bad oil consumption. Compression test will be done tomorrow when a friend brings over the kit.

2.) Defective breather box since it was an aftermarket part.

3.) Bad breather box install. When replacing, we attempted to remove the rubber hose between the breather box and the oil bath and failed, ripping the hose. We remove the free pieces of rubber and installed the box without replacing the rubber hose, as we did not have the means to lift the engine and pull the oil pan. We theorized that while not ideal,this should still vent the crankcase pressure but with the possibility of additional oil consumption.

Do any of these ideas make sense? Any problems with aftermarket breather boxes? Any other possible causes that may be causing the oil consumption? I am hoping to get some feedback before I go out and buy the replacement parts I need.

Thanks,
Brian