TheSamba.com :: View topic - Syncro fuel tank removal advice needed (Solved)

Mon Nov 08, 2021 2:59 pm

I am in the midst of removing the gas tank on the syncro.

My word what a biotch.

I understand from other topics and references that the drivers side needs to be lowered first and that the fuel level sender will hang up on the frame member. I am using the recommended 4 foot pry bar on the top of the tank and the 1 foot pry bar on the side to push in the sender so the studs will clear the frame member.

For the life of me after an hour I cannot get it past this point. I am so frustrated I am about to take a sawzall to the tank and make quick work of it.

Please give me advice on what I should be doing.

Help!

Mon Nov 08, 2021 3:11 pm

I think I ended up using a second prybay to push the sender area in towards the tank. the tank has a bit of flex, enough to make clearance for the studs... one at a time.

Make sure the opposite end is up and pushed over toward the passenger side as far as possible.

You may want to try removing the sender, than dropping the tank... I told myself I would try that if I ever had to do the job again.

Have fun getting it back in. Maybe have a spare vent valve ready (I broke one while wrestling with the tank back in. Of course I didn't notice until it was all back in place.

If you are replacing the sender, test it first. after reinstalling my tank I found out my new sender was NFG.

Have fun!

Mon Nov 08, 2021 3:16 pm

🤷🏼‍♂️ I ain’t never seen one of those!

Mon Nov 08, 2021 4:00 pm

Wrap some hard plastic, like a split laundry detergent bottle, around the frame rail. That gives things an opportunity to slip by vs grab on the frame rail.

Mon Nov 08, 2021 4:43 pm

Sure glad I don't got no Syncro. 1WD seems to work for me.

Duncan

Mon Nov 08, 2021 5:10 pm

Wear safety glasses to keep the crud out of your eyes.
Facemask isn't a bad idea either!

You could get extravagant and put the tsnk under vacuum pressure to shrink it a little!(that's just fantasy! 😁)

Mon Nov 08, 2021 5:18 pm

Exactly, slip a tough plastic sheet up between the sender studs and the frame rail so the studs can glide over the frame rail edges.
Do the same to reinstall the tank.

I cut the side off a coolant jug. Tough and slippery.

Mark

syncrodoka wrote: Wrap some hard plastic, like a split laundry detergent bottle, around the frame rail. That gives things an opportunity to slip by vs grab on the frame rail.

Mon Nov 08, 2021 5:25 pm

You should put away the Sawzall. You would definitely regret that later.

It was a long time ago, but I did what syncrodoka is suggesting. I think I used a sheet of thin UHMW or nylon that I had here. Push it back up, and as dschaftlein suggested, get the far side up and as far to the PS as possible. The thin hard plastic helps keep the sender side from hanging up as badly.

I don't recall using a prybar on top of the tank, but as I said that was a while ago so I am not sure. And the connector was already broken on mine, and the screws and nuts completely rusted, so I was not too worried about damaging anything.

RonC

Mon Nov 08, 2021 5:56 pm

Now you know why I call it the "Mother of all Fuel Tanks".

Mon Nov 08, 2021 7:35 pm

DuncanS wrote: Sure glad I don't got no Syncro. 1WD seems to work for me.

Duncan

same useless comments that the aircooled crowd says when they hear about a coolant leak on a van... wow glad I don't gots me one of those.. sounds like trouble...

/SMH. :roll:

as for the OP issue, I keep those flexible cutting board 'sheets' handy for such things.. but a detergent bottle sounds slippery enough too. :idea:

Mon Nov 08, 2021 7:41 pm

OK. I’ve got the thin cutting board material recommended. This tank is coming out tomorrow one way or the other. And it is a ‘mutha’. :lol:

Mon Nov 08, 2021 8:16 pm

I'm not disparaging the Syncro. It is a fabulous vehicle for many. It's just not for me as I don't need its attributes nor expenses.

Duncan

Mon Nov 08, 2021 8:20 pm

DuncanS wrote: I'm not disparaging the Syncro. It is a fabulous vehicle for many. It's just not for me as I don't need its attributes nor expenses.

Duncan

That's fine. So just don't post replies like you did in Syncro threads.
No offense, but it gets tiresome for Syncro owners looking for maintenance advice to see comments about how some Vanagon owners are so glad they don't own Syncros.
It's just not helpful.

Mon Nov 08, 2021 10:05 pm

photogdave wrote: DuncanS wrote: I'm not disparaging the Syncro. It is a fabulous vehicle for many. It's just not for me as I don't need its attributes nor expenses.

Duncan

That's fine. So just don't post replies like you did in Syncro threads.
No offense, but it gets tiresome for Syncro owners looking for maintenance advice to see comments about how some Vanagon owners are so glad they don't own Syncros.
It's just not helpful.

I get it, I see it happen a lot to people looking for WBX repair advice. What they so often get instead is ........ "put a Subaru in it".

Anyway...... back on track, looking forward to seeing that tank on the floor!
Hopefully it is empty of fluids........

And why do I see rust repair in your future?.........

Dave

Mon Nov 08, 2021 10:16 pm

Hah! The only fluid in that tank is a gummy mess from 15 years of sitting. Notice that the drain hose is not plugged.

Does not seem to be structural rust yet. But plenty of surface rust to deal with. We will see what awaits behind the tank….

Mon Nov 08, 2021 10:50 pm

This is the link you want https://www.thesamba.com/vw/forum/viewtopic.php?t=354632&highlight=syncro+fuel+tank

I used a couple pry bars to do mine and John Maws. Not something that I'm ever looking forward to again.

Tue Nov 09, 2021 6:24 am

This worked for me:

http://syncro.org/removing-the-syncro-gas-tank/

Good luck!

ETA: This post hole digger pole was the tool that finished the job:

Tue Nov 09, 2021 6:52 am

Thanks folks. Those are helpful references.

I'll be back at it this afternoon. :P

Tue Nov 09, 2021 7:32 am

You've almost got it!, just keep pushing it toward the right side of the van as you pry it down. It is pretty tight but it really is not that bad of a job once you've done it a couple of times. A good quality long pry-bar is your friend for this job.

Tue Nov 09, 2021 8:32 am

A second pair of hands with a second crowbar can work wonders. You're at the hardest spot, a few more inches and it'll be out!

Just keep prying!