View original topic: Syncro fuel tank removal, reseal and SS strap install Page: 1, 2, 3, 4  Next
HeftySmurf Mon Apr 27, 2009 9:54 pm

Dropped my fule tank on my Syncro, put in SS straps and a SS piece that goes on the inside of the tank. The directions helped immensly compared to the Bentley.The old ones where in good shape though, prolly will go in my other Syncro after I clean them up and POR them. No major rust either, cleaned it up real nice put Mortons truck bed liner in there (3 coats) and resealed and replaced all the vent lines.... havent put it back in yet... Oh yeah I por 15d the part that attaches to the fuel pump as well.
Also undercoated the entire van and engine compartment as well (including the space behinde the taillights.)
Panel waxed all the interior panels and any part underneath I could get to.
Sound deadening is next and then I drop the Zetec in.... t more weeks and on the road I hope..

Ill have some more pic of the final product soon.....

doublez72 Tue Apr 28, 2009 5:00 am

That was quite the job, I wished I would have taken the time and done that before my Zetec went in. I've been down without a tranny and just waiting to get it fixed. I might just try to drop my tank and do that. Please post the pictures of the install. That will help me when I try this project.



goskiracer Tue Apr 28, 2009 6:02 am

what kind of undercoating did you apply? Any pics? I am getting shipped to Ohio and want to keep my syncro in its rust free condition.

HeftySmurf Tue Apr 28, 2009 6:27 am

I used Mortons truck bed liner and panel wax Terry Kay recommends on his site. first I por 15'd any rust prone spots like seems and behinde the fuel tank and above the transaxle. I have the radiatior, front diff, coolant lines, headlights etc out. One spot you must get is behinde the tail lights, that is the root of the seam rust in those areas. Passenger side is a bitch to get to with the gas tank filler line in the way and the snorkle. I soaked it in Marine clean, Metal Ready, then POR'd it. After that I coated the entire inside the the bed liner. After that I coat that with some panel wax becausde it seeps into any crack that might be there.
I degreased everything and sprayed behinde the radiator, headlights. I also POR'd the radiator fan housing and mounts. From looking at rusty Syncros those seem to get pretty rusty. While everthing is out i plan on spot blasting the interior of the wheels to get at the seam. I have very minimal seam rust on the out side, but I can see cracks in that old undercoating that if left untreated will guarantee future problems.
Just a reminder, at first I planned on POR everything, after using it on some other things, it is best to use it only on spot with rust so it has something to grab onto.
I will for sure have more pics, I plan on doing a big post when my van is on the road finally.

HeftySmurf Tue Apr 28, 2009 6:33 am

BTW, just dont drive it in the winter

snowsyncro Tue Apr 28, 2009 10:05 am

HeftySmurf wrote: BTW, just dont drive it in the winter

But...but....that's when you need a Syncro! :lol:

Nice job on the tank; just be thankful you don't live here. You don't want to see mine -- it will make you throw up in your mouth -- just a little bit.


HeftySmurf Tue Apr 28, 2009 11:12 am

Yeah I saw your rusty exhaust and a little bit of puke came up LOL
Thats why I plan on moving out west

iceracer Tue Apr 28, 2009 11:23 am

Wanna see rust? You should see the syncro I am restoring. Go look at Bens website and some of the rust repairs he has done and that is how mine looks. I too had the tank out and sandblasted the underside of the van and then treated and por15'd every inch by hand. Crazy work. That was last year and now I am finishing up welding and soon will be doing the bodywork. 2 yr project. I think I should have junked it, but it is a sickness I can not explain.

HeftySmurf Tue May 05, 2009 10:16 am

Some more pics, still have to reinstall
Enjoy :lol:

Still need to POR behinde there (thats were the rust is coming from on that seam)

snowsyncro Tue May 05, 2009 4:32 pm

HeftySmurf wrote: Some more pics, still have to reinstall
Enjoy :lol:

I did! Looks great. Excellent job.

So, is that before the truck bed liner and wax?


HeftySmurf Tue May 05, 2009 5:48 pm

The first set of pics is, before...... :roll:

snowsyncro Tue May 05, 2009 6:04 pm

HeftySmurf wrote: The first set of pics is, before...... :roll:

Of course they are... :P

Sorry for the confusion. I was asking if the last set of pictures was taken after the POR15, but before the truck bed liner and wax, or after the complete treatment, including the truck bed liner and wax. :)


HeftySmurf Tue May 05, 2009 6:08 pm

Lol I know,....
Yes the are after the POR, used the wax in the spot in the chasis and behinde the tail lights

HeftySmurf Sat Oct 24, 2009 12:18 pm

Here's a more condensed post
I did this a few months ago a biscally full reconditioning of every bushing, hose, etc on the underside of my syncro. Allot of work but worth it
Here's a list of what I did
resealed tank
Hydrolic hose PS lines
All new vent lines
fuel pump
fuel filter
SS tank straps
SS piece the sender attaches to
New SS coolant lines
Entire scapping of underbody and POR on rust and 3 coats of truck bedliner follwed by a coat of wax on everything and spray grease on any nuts and bolts
Cleaned, POR rusty spots only and did Mortons truck Bed liner (3 coats) every where else
Did the same thing to the entire engine bay
Also take the time to get the area behinde each of the taillights to scrape out the old seam sealer and replace it. This is th esource of the most common rear panel seam rusting form water and condensation from the temp changes inside the engine bay. Additionally who may want
Change the bushing in your shift linkage, the boot off the transaxle, make sure your vaucuum actuators are good

Additionally Anthony J. on the classifieds sells all the stuff mentioned and has better prices than the vandors and has Stainless stuff they dont have:
Here are whole bunch of pics

Using a 5ft pipe to get it out

New stuff goes in

cleaned up and resealed

Sandblasted and painted with POR

New radiator

HeftySmurf Sat Oct 24, 2009 12:21 pm

Pics of the seams behinde the tailights
Picked, dremeled, and Sandplast

edbee Sun Nov 29, 2009 12:55 am

Great photos!

I am just getting started on the same task (adding a Zetec too) only mine is more rusted above the tank than yours appeared to be. Did you find it relatively easy to remove that thick sound deadener/insulation pad from above the fuel tank? I don't want to wreck it as I remove it.

Where did you get your power steering lines? And the SS coolant lines, from where and are you happy with them?

I did buy the stainless tank mounts from Anthony and was thinking about the sending unit retainer ring too.

I plan on posting photos sometime soon.

Thanks again for your detailed info!
Ed - North Vancouver, BC

CinnabarVan Thu Feb 04, 2010 6:38 am

Thanks for all the information and pictures on the steps to do this crazy job. It is well worth it seeing how rusty the frame was behind and above the tank.

I will try to add a couple additional pictures of a North East van with 24 years of road rage accumulated.

CinnabarVan working on Stella Blue

kenwilfy Thu Feb 04, 2010 6:52 am

I am just finishing this job up for a customer myself. I appreciate the pictures very much. Actually it was my search for a fuel tank sender for this customer's van that led me to start importing them for customers along with many other products that can only be gotten in Germany now.
My particular syncro is from Delaware and it was rusty in different places but not to the point of causing any structural concerns. However the rear section of brake lines had to be replaced and the power steering lines are shot. I make and sell the power steering hoses as a kit for $225 if anyone is looking for them. I also had to fabricate two new mounts for the front mounts that the gas tank straps attach to. The original gussets were rusted out at the bottom so I had to make new attachment points for the straps in the front. I just used two pieces of light angle steel and then welded nuts to them and painted them black. Then I riveted them to the frame with stainless steel rivets. Seem to be very sturdy. I replaced all of the vent lines on the top of the tank and the sender unit with a brand new OEM one (I sell for $199). I will try to post some pictures later on today or tomorrow.

iceracer Thu Feb 04, 2010 7:34 am


I too replaced all hard brake lines when I did mine. And also had to reinforce the tank strap attachment points. Lots of dirt and crud and rust in there from years of use. And I have a set of your power steering lines I will be installling in the coming month.

edbee Thu Feb 04, 2010 11:46 am


iceracer: for the hard brake lines did you just buy metal line in bulk and bend/cut/flare them as needed or did you buy them all individually made to fit (if they are available like that.) I need to replace most of my metal brake lines too. for photos

Ken: do you have photos of the power steering lines you sell? I just ordered the sending unit from you yesterday (with SS ring) but might have ordered the PS lines had I know you had them too.

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