TheSamba.com :: View topic

Sun Jul 26, 2009 2:02 pm

Symptoms are: gas smell even though all my vent lines are good and the charcoal canister is hooked up, a dime-sized spot of gas on the ground when I fill up, and spilling gas when I take a turn.

After investigating, I found a crack in the fuel filler neck so wide I can just about stick my finger through. I'll be ordering one from Bus Boys tomorrow.

This is a job I can do with the engine in place, right? I've heard mixed things. Right now I've gotten the firewall removed and the pie plate off and ECU removed, so I can reach my hand up and feel where the filler neck connects. It seems like if I can loosen the clamps I can wiggle it free, then put in the new one.

Any sage advice? Words of encouragement? 8) Thanks

Sun Jul 26, 2009 2:06 pm

What's dreaded about it? Why would you even consider pulling the engine? There isn't one part of the engine in the way of the fuel filler neck. I've had to replace the neck on every Bay Bus I've ever had, and never really found it to be all that difficult. You should be able to switch it out in a few minutes.

Sun Jul 26, 2009 2:17 pm

It's a little hard to get it clamped at the right angle. I found it easier to remove the length of pipe from the tank to the filler neck without disturbing the boot. Then install the new boot at the same angle and replace the pipe.

jim

Sun Jul 26, 2009 2:18 pm

although our original fuel tank filler hose is good with no cracks, we decided to replace it when the tank was out. We bought one from Napa as described by Richard Atwell but these Napa only had the Mexican hose which is too rigid and would not work. We got a piece from Scott at German Supply and it went on pretty easily although I am doing it while the engine is out. The piece can be replaced while the engine is in, however it is one of those things you plan to do as PM while working on an engine that is out. If you are replaceing the elbow, we were lucky and found a NOS one plus a metal restrictor plate. It was really easy to put on. I have not seen the parts from Walter but the Bus Boys has been good to me on everything so I would assume it would work well.

Sun Jul 26, 2009 2:34 pm

You're making me feel better already, thanks. This will be the last original piece of rubber in the fuel system to replace.

Sun Jul 26, 2009 3:30 pm

lostorbit wrote: You're making me feel better already, thanks. This will be the last original piece of rubber in the fuel system to replace.

Just want to make sure that you know there are two pieces of rubber in the fuel filler pipe system. One right at the tank and the other right at the cap. You probably will want to do them both while you are at it.

Sun Jul 26, 2009 3:37 pm

Yeah, to be clear I was talking about the elbow. The rubber at the other end of the pipe going into the tank has already been replaced, and it's still in good shape. I inspected it along with the vent lines coming out of the tank.

I just pulled the elbow out and it was worse than it looked like. It's split all along the bottom.

Sun Jul 26, 2009 5:36 pm

We need to find a metal replacement for the elbow. Not sure why VW decided to use rubber there. Maybe there is a good reason, but I don't know it. Surely there is an all metal elbow out there on something that would be a perfect fit.

Sun Jul 26, 2009 9:13 pm

Wildthings wrote: We need to find a metal replacement for the elbow. Not sure why VW decided to use rubber there. Maybe there is a good reason, but I don't know it. Surely there is an all metal elbow out there on something that would be a perfect fit.
Dammit, that does it. I'm now officially on a quest to make a METAL one. Stainless , maybe.
I have replaced my stock one, and it is not that bad to do.
But a metal one will last, oh, maybe FOREVER. :lol:

Mon Jul 27, 2009 4:47 am

Nice job man! You've motivated me to finally give mine a go :twisted:

So do you unscrew anything from outside the filler to remove it? Looks like there's screws that go through.

What retailer would have that part for a '77 Bus? And the lower one that go's to the tank?

Mon Jul 27, 2009 5:54 am

77VWBusDude wrote: So do you unscrew anything from outside the filler to remove it? Looks like there's screws that go through.

Right, so here's what I did to get the old one out. I first removed the firewall (don't forget the two bottom screws) after removing the intake and other hoses and such in the way on top of the engine. I also popped off the pie plate and removed the ECU. I loosened the clamps on the rubber hose going into the tank and put a rag on top of the opening to keep anything from falling in.

On the outside of the bus, remove the gas cap and unscrew the four screws holding the metal ring in place. With those out of the way I could grab the edge of the rubber elbow and push it into the opening. That's the only way I could get a small screwdriver in place to loosen the clamp on the elbow and pull it off.

77VWBusDude wrote: What retailer would have that part for a '77 Bus? And I should replace the lower one that go's to the tank as well.

Everyone says the elbow from Bus Boys is the best one to get, but it's also available from Bus Depot and CIP. I'm calling Bus Boys later today to order one.

I'd replace the lower hose too while you're at it. Apparently you can get a 4-1/2 inch diameter hose from NAPA that fits pretty well. I replaced mine years ago and it's still in good shape.

Mon Jul 27, 2009 6:00 am

lostorbit wrote: Everyone says the elbow from Bus Boys is the best one to get, but it's also available from Bus Depot and CIP. I'm calling Bus Boys later today to order one.

I'm not sure who "everyone" is, but the filler neck from BusBoys, CIP1 and BusDepot are all the exact same part. It's a genuine VW part and is sold at any ACVW supplier. Tough for one to be the "best" when they are identical parts. I got mine from CIP1.

Mon Jul 27, 2009 6:11 am

That's good to know, seems like the original was NLA for a long time and there were some less-than-perfect repros out there.

Bus Boys does have the cheapest price before shipping.

Mon Jul 27, 2009 9:02 am

I ordered the filler neck originally from Bus Depot and it was NOT the same as the one I ended up using from Bus Boys... smaller size, thinner walls... just felt cheap. The Bus Boys filler neck is the way to go.

Mon Jul 27, 2009 9:48 am

Just did mine yesterday. Unfortunately, we did have to pull my engine out slightly, because I have a Type 1 instead.

Since you're already going through the trouble of replacing your neck, you should replace the large fuel hose that connects to the tank. Depending on whether you have an earlier or later bay, you may have the short metal elbow and a long piece of hose, or a long metal fuel neck and a short piece of hose on the end.

If your filler neck is cracked or worn, chances are those hoses are too. Mine had cracks all over it when I finally pulled it out and was able to inspect it.

If you do have an earlier bay, don't bother trying to find the long fuel hose. Just try to source a long fuel neck from a later bay and adapt some straight fuel hose to the end, or go to a muffler shop and have them fabricate you an elbow with the appropriate bend.

vw76westy posted great photos of his solution in this thread:

http://www.thesamba.com/vw/forum/viewtopic.php?t=288112&highlight=fuel+neck

It may be a little tight when you put the fuel hose on the end. Though you may feel a bit strange and getting too friendly with your bus, use vaseline to make it fit onto the metal neck. It also makes it easy to get on the end of the fuel tank.

Also, when you are putting the whole assembly in, you may find it cramped and frustrating. Fear not, everything will fit, but it's annoying. Put in the end with the hose through the hole with the paint can lid and slide it along the wall. Rotate and get the end with the filler neck and maneuver it up to the hole where it will be screwed so it stays fixed. A helper on the outside of the bus makes that part much easier. After that, just bring the hose around and connect it to the tank. Clamp the shit out of your hoses and you're all set

Good luck!

Tue Jul 28, 2009 8:58 am

I Have a 73,
not sure what to do. I Have the long rubber gas filler hose and bus boys nor bus dept. have the filler neck so reading the last post I should just get a metal one fabricated, and attach it with two rubber boots on each end, that does not make since to me because it seems there a more places for the seal to brake crack come lose, does anyone know where I can get the fuel filler neck for a 73 bus, or get another hose that will work.
Also where can I get those little pads that go under the gas tank?
thanks

Tue Jul 28, 2009 9:36 am

VDubTech wrote:
I'm not sure who "everyone" is, but the filler neck from BusBoys, CIP1 and BusDepot are all the exact same part. It's a genuine VW part and is sold at any ACVW supplier. Tough for one to be the "best" when they are identical parts. I got mine from CIP1.

patayres wrote: I ordered the filler neck originally from Bus Depot and it was NOT the same as the one I ended up using from Bus Boys... smaller size, thinner walls... just felt cheap. The Bus Boys filler neck is the way to go.

:?

Tue Jul 28, 2009 9:46 am

Nater'D wrote: I Have a 73,
not sure what to do. I Have the long rubber gas filler hose and bus boys nor bus dept. have the filler neck so reading the last post I should just get a metal one fabricated, and attach it with two rubber boots on each end, that does not make since to me because it seems there a more places for the seal to brake crack come lose, does anyone know where I can get the fuel filler neck for a 73 bus, or get another hose that will work.
Also where can I get those little pads that go under the gas tank?
thanks

Someone in Europe has the original hose, but I can't find the link, it was quite expensive, IIRC. You might search back three or four years through old post on filler hoses and see what you can find. I think you are wasting your time and worrying needlessly though, 75 and later buses all used the bent pipe with the extra joints and don't give any more problems than the earlier buses with the formed hose.

Tue Jul 28, 2009 9:50 am

Nater'D wrote: I Have a 73,
not sure what to do. I Have the long rubber gas filler hose and bus boys nor bus dept. have the filler neck so reading the last post I should just get a metal one fabricated, and attach it with two rubber boots on each end, that does not make since to me because it seems there a more places for the seal to brake crack come lose, does anyone know where I can get the fuel filler neck for a 73 bus, or get another hose that will work.
Also where can I get those little pads that go under the gas tank?
thanks

OEVEEDUB has the neck in stock and it is under $10. Will report back once mine arrives.

Tue Jul 28, 2009 10:32 am

Nater'D wrote: I Have a 73,
not sure what to do. I Have the long rubber gas filler hose and bus boys nor bus dept. have the filler neck so reading the last post I should just get a metal one fabricated, and attach it with two rubber boots on each end, that does not make since to me because it seems there a more places for the seal to brake crack come lose, does anyone know where I can get the fuel filler neck for a 73 bus, or get another hose that will work.
Also where can I get those little pads that go under the gas tank?
thanks

My original neck had the fuel filler neck with a short metal piece and a longer fuel hose that connected to the tank, which is only available from a French site that sells it for around 75 Euro.

Instead of dealing with that, this is what I got off of a later bus:

I just used a straight hose on the end and clamped it really tight. However, if I were to do it again, I would cut the end at a slight angle so it fits properly on the tank end.

If you cannot find a neck from a later bus, then you can do something like this: