TheSamba.com :: View topic - Best way to change rubber boot for gas tank filler neck?

Fri Apr 26, 2019 9:09 am

I did the same as Pittwagen ^^

Removing the firewall without at least dropping the engine a bit is possible, but not easy.

I could not remove the metal filler pipe no matter how I turned it with the gas tank still in place, so I did the same as Pittwagen and installed the rubber top curved part making sure to align it right, while the metal pipe was still in there. I used the pie plate for access too.

At the end of everything, I still had fuel leaking from the filler at the top.

I ended up using a gas resistant sealer to seal around the filler hose at the gas cap as it was not sealing properly to the body. No more leaks now.

Fri Apr 26, 2019 10:20 am

vwwestyman wrote: I think I cna get to the clamps without removing my engine, which I hope is true, because it is a PITA!
I'm just able to get to mine through the pie plate hole and tighten/loosen the clamp at the filler end of the pipe, so you should be able to unless there's more stuff in that area on your TDI than on my 1.8T. Takes a good bit of contortionism -- if there was an extra joint between the elbow and wrist it would be a lot easier. How are you at working on things you can't see? Good mental visualization helps a lot with working on things you can't see .. it's a skill one develops over time with lots of practice. :lol:

Fri Apr 26, 2019 6:23 pm

I just did mine two months ago on my 77. I laid the firewall on the engine after removing the s boot, then I removed the ecm and pie plate. After removing the lower hose to the tank remove the rubber elbow with the metal filler tube through the piehole as one piece.

Mark the rubber elbow and metal tube before separating them. Then the new one can be aligned in the same orientation.

I'd use what people said above about the tank to metal tube connection from (dodge or mercedes?) having the bend. The one I got from BD was strait and the worst part about doing this project. It was tight. I also used spray silicone to help the rubber slide easier.

Thu Jul 10, 2025 10:40 pm

OK, reviving this thread. Back in 2019 I redid ny fuel lines including the fuel filler hoses. When I fill the tank to pump shut-off, gas spills out of the filler and down the outside of the bus. I can't for the life of me figure out how it is getting there. The rubber elbow was new in 2019 and is still in good shape. I can tell by look and feel that it is not cracked, broken or attached insecurely to the pipe below. New metal ring and new gas cap in 2019 also. They seem flat and tight. Good rubber on the gas cap. Seems to seal well. So how is the gas getting out?

I don't have a problem doing the mod that Skills did to replace the rubber elbow from the inside top, but it doesn't look like it needs replaced.

Any ideas? I try stopping filling before the pump shuts off, but it's a guessing game and doesn't always work.

Fri Jul 11, 2025 9:11 am

I had something similar a few years ago where I found a small cut in the rubber elbow right up just under the fuel cap. However, the fuel was leaking down on the inside, not the outside of the Bus.

I couldn't see or feel it until I took it apart. Not sure if you are having a similar issue but once I installed a new one, no more issues.

Fri Jul 11, 2025 9:48 am

Thanks. Yes, logically it seems like the only way it can be leaking is from a faulty seal on the gas cap. It seems fine, but I wonder if that is the problem...

Fri Aug 22, 2025 7:58 am

I've noticed that each time I fill up over the last few weeks that the gas nozzle somehow gets caught and I have to lift and move it around to remove the nozzle after filling. I guess that I must have damaged the rubber filler boot removing the nozzle as I've had a gas fume smell the last few days.

I relocated my fuel pump and replaced all the fuel hose from the tank to the engine recently installing the A/C so I thought one of the fittings was leaking or a clamp needed to be tightened but after checking everything, there were no leaks or sweating.

I checked the rubber filler boot yesterday and noticed a small rough area at the lip so I think I tore a small hole or punctured the boot pulling out the nozzle. I will order a new rubber boot but in the meantime I took some HD roofing tape (Gorilla Brand) that I had left over, cut a few pieces, cleaned the area, and patched over the damaged lip.

The roofing tape adhesive is really sticky and not fun to work with but it sealed up the boot well and now no more gas fume smell. This should work until I get a new rubber filler boot and I may add a piece to the new boot to reduce the chance of the same thing happening again.

The roofing tape seems to be a good temporary solution.

Fri Aug 22, 2025 8:46 am

I rigged up a hanger to support the metal fill pipe,so it would not be hanging from the rubber connector.might help might not.