Best way to change rubber boot for gas tank filler neck?

[7eightchampagne]

Hey folks I'm wondering the best way to change that rubber boot that connects the filler neck to the gas cap ring. I really don't want to pull my motor but the smell of fuel is to much to handle thanks

[sjbartnik]

The best/easiest way is to pull the engine.

Then you can easily remove the firewall panel and gain access to the filler boot but also all the little rubber vent lines in there that are probably also rotted.
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[Angus II]

Hello,
Haha, you're funny. Pulling the engine is the only way, my friend...
Well, you could cut out the rear cargo area and maybe get too it.... it's covered by the pad, No one will see your hack.
May as well put new shifter shaft bushing in when the engine and tranny are out...

[alman72]

why not give the pie plate a shot? someone JUST posted recently about this. It will either be reachable, or it wont. the consensus was that doing the swap thru the pie plate hole was misery.
edit, btw, your fuel smell could be from 3 or 4 different reasons
bad filler neck
bad connections on evap system
leaky fuel lines
bad seal on fuel level sensor
anyone else want to jump in?

[7eightchampagne]

Dang ya I was thinking the pie plate. I have to change the battery tray but I think I can do that with the engine in. My bus runs and drives great so I don't really want to pull it but it's looking like I might have to

[alman72]

pop the plate and see if it is doable. the guy on here a couple days ago said he watched a video where the clamps were right behind the plate when popped off. the real life attempt had no such luck

[Angus II]

Hello,
Heck, it's only 1 hour maybe 2 at the most to pull the engine and tranny as an complete assembly, from start to finish. Well, that's if you've done it before and know what tools you will need "with you", so as not be crawling out for everything.
Then it would be easier for replacing the battery pan also. It's your free time, not mine...
Oh, and take care of the fuel tank(gas fumes) before you get in there with the welder......either way you decide to go. Safety first...

[skills@eurocarsplus]

just do this

I hate doing stuff like this but the only available boots are made out of shit coated Chinese tissue paper...and I suspect you will do this every year/18 months.

seriously...they are that trashy. the source for good OEM ones has dried up last I checked. so what we are left with are all junk...WW CIP etc...they all sell the same paper thin ones
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[vwwestyman]

[ivwshane]

I might have asked this before but I don't remember the response. Could the material gee bee uses for the hoses he reproduces be used in this application? I find his products to be superior to whatever after market stuff their is and even better than OEM stuff.

https://www.thesamba.com/vw/classifieds/search.php?username=GEEBEE
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77 westy 2.0 FI
69 ghia coup 1600dp
70 single cab

[skills@eurocarsplus]

you would have to see if he could do it. I think the way he layers it would make it far too thick to seat in the gas cap area
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[aeromech]

The filler neck to the gas cap ring? Do you mean the filler neck to the tank? What year is the bus? I’m assuming you’ve never dropped an engine before and it’s scaring you. Just know this, if you drop the engine, remove the firewall, pull the tank and look inside, then replace all the 40 year old rubber hoses you’ll be glad you did. Does the gas smell only happen when you top off the tank?
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[7eightchampagne]

The neck to the out side of the bus the bus is a 78 it kinda has that stale gas smell anytime the tank is half full or more and no I havnt taken one out myself I have a couple parts buses one with that the motor and tranny need to come out of so looks like I'll pull that one as practice then on to mine I suppose. I have a 76 westy with no motor so I do know about those other hoses in there

[Wildthings]

[mtcamper]

I did this last year. The replacement rubber piece I got to replace the old birds beak style filler neck was so crappy I just decided to keep the original as it is in ok shape. The tube from the tank to the tube was very warn and cracked. I replaced that with a sprinter van fuel hose. I believe it's part # 5119668AA . It worked great and I now have no more fuel smell.

[ivwshane]

[vwwestyman]

[skills@eurocarsplus]

[ivwshane]

[pittwagen]

I replaced the top filler piece and the lower hose along with all the vacuum hoses almost 9 years ago. I did not remove the engine. I did remove the firewall and pie plate. It was necessary to remove the S boot and air filter housing etc. Took about 4 hours total.

Just one note. Because the filler neck rubber piece is not as heavy duty or rigid as the original it can be attached to the pipe and then fed up into place and pulled carefully through the top opening. It does need to be oriented correctly on the pipe before the clamp is attached. I did not install the upper metal ring until the lower hose was attached to the pipe and tank.

And do not jam the filler nozzle into the upper pipe area when filling at the gas station. The filler neck rubber piece will last much longer. 9 years in about 2 months. FYI.