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vwuguy 
Samba Member
Joined: November 01, 2005
Posts: 1053
Location: southwestern ontario, on and netherlands and bc
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 Posted: Mon Oct 30, 2017 2:22 pm Post subject: How to replace your fuel sending unit in your baywindow bus |
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Here erb shows you how to replace the fuel sending unit without hacking a hole into your very rare kombi bus
It all started with "shit the fuel gauge stopped working!"
part 1
Link
part 2
Link
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MrBreeze
Samba Hitman
Joined: October 06, 2002
Posts: 5537
Location: Lawn Guyland, Noo Yawk
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| Posted: Mon Oct 30, 2017 3:19 pm Post subject: Re: How to replace your fuel sending unit in your baywindow bus |
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Wish my PO had seen that. I have a hacked hole that looks like he used a rusty butter knife to make.
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WTB: Bay Shore or Queensboro VW Frames
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Brian
Samba Moderator
Joined: May 28, 2012
Posts: 8340
Location: Oceanside
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| Posted: Mon Oct 30, 2017 4:20 pm Post subject: Re: How to replace your fuel sending unit in your baywindow bus |
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I'll give a beer to the first person who watches all 3 hours non-stop
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Wildthings
Samba Member
Joined: March 13, 2005
Posts: 50337
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| Posted: Mon Oct 30, 2017 8:26 pm Post subject: Re: How to replace your fuel sending unit in your baywindow bus |
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| Brian wrote: |
| I'll give a beer to the first person who watches all 3 hours non-stop |
It certainly won't be me. I clicked on the video and saw how long it was and moved on.
I don't consider a hole in the rear deck a hack, especially since VW recommended doing it and it is totally concealed by the carpet. Not only does the hole allow you to quickly change out the sender but you can visually check the tank for foreign objects and water.
On my present transporter, I cut the hole when I was first getting the rig road worthy and needed to change out the sender. A year later the sender failed again and this time the replacement took only minutes to do.
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vwuguy
Samba Member
Joined: November 01, 2005
Posts: 1053
Location: southwestern ontario, on and netherlands and bc
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| Posted: Mon Oct 30, 2017 8:55 pm Post subject: Re: How to replace your fuel sending unit in your baywindow bus |
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It is worth watching grab some popcorn and go for it..
I guess the hole is only important depending on how rare your bus is maybe..
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skills@eurocarsplus
Samba Peckerhead
Joined: January 01, 2007
Posts: 16863
Location: sticksville, ct.
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| Posted: Tue Oct 31, 2017 4:54 am Post subject: Re: How to replace your fuel sending unit in your baywindow bus |
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has nothing to do with how rare anything is, it's how clean the hole is done. look close...you can hardly see the access panel
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| gprudenciop wrote: |
my reason for switching to subaru is my german car was turning chinese so i said fuck it and went japanese....... |
| Jake Raby wrote: |
| Thanks for the correction. I used to be a nice guy, then I ruined it by exposing myself to the public. |
| Brian wrote: |
| Also the fact that people are agreeing with Skills, it's a turn of events for samba history |
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vwuguy
Samba Member
Joined: November 01, 2005
Posts: 1053
Location: southwestern ontario, on and netherlands and bc
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| Posted: Tue Oct 31, 2017 12:36 pm Post subject: Re: How to replace your fuel sending unit in your baywindow bus |
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From my perspective,
I really like the bus and spent much time trying to keep from adding anything but stock holes to this bus..
If it was a barndoor would you cut a whole into it to access the gas tank too?
I have cut the hole into the top to to fix a late model bus quickly however
cutting a access hole into it is not the way it says in the manual.. and if you have the time the correct way is better i'd say.. no extra holes.. that need to be welded and fixed..
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skills@eurocarsplus
Samba Peckerhead
Joined: January 01, 2007
Posts: 16863
Location: sticksville, ct.
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| Posted: Tue Oct 31, 2017 12:51 pm Post subject: Re: How to replace your fuel sending unit in your baywindow bus |
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| vwuguy wrote: |
From my perspective,
I really like the bus and spent much time trying to keep from adding anything but stock holes to this bus..
If it was a barndoor would you cut a whole into it to access the gas tank too?
.. |
1) a barndoor tank is filled by opening the engine hatch
2) I would Subaru the fuck out of a barndoor.
it's just a car....they made millions of. enjoy it as you see fit. but I will tell you this, when your china sender takes a shit and you are doing this once a month, you too will pull the sawzall out
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| gprudenciop wrote: |
my reason for switching to subaru is my german car was turning chinese so i said fuck it and went japanese....... |
| Jake Raby wrote: |
| Thanks for the correction. I used to be a nice guy, then I ruined it by exposing myself to the public. |
| Brian wrote: |
| Also the fact that people are agreeing with Skills, it's a turn of events for samba history |
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Xevin
Samba Member
Joined: January 08, 2014
Posts: 7624
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| Posted: Tue Oct 31, 2017 12:58 pm Post subject: Re: How to replace your fuel sending unit in your baywindow bus |
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| vwuguy wrote: |
From my perspective,
I really like the bus and spent much time trying to keep from adding anything but stock holes to this bus..
If it was a barndoor would you cut a whole into it to access the gas tank too?
I have cut the hole into the top to to fix a late model bus quickly however
cutting a access hole into it is not the way it says in the manual.. and if you have the time the correct way is better i'd say.. no extra holes.. that need to be welded and fixed.. |
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Keep on Busin'
| 67rustavenger wrote: |
GFY's Xevin and VW_Jimbo!  |
| Clatter wrote: |
| Damn that Xevin... |
| skills@eurocarsplus wrote: |
I respect Xevin and he's a turd  |
| SGKent wrote: |
My God! Xevin and I 100% agree  |
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wcfvw69
Samba Purist
Joined: June 10, 2004
Posts: 13389
Location: Arizona
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| Posted: Tue Oct 31, 2017 1:13 pm Post subject: Re: How to replace your fuel sending unit in your baywindow bus |
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| skills@eurocarsplus wrote: |
| but I will tell you this, when your china sender takes a shit and you are doing this once a month, you too will pull the sawzall out |
I was curious about this so I poked around looking to see if the VDO fuel senders were still available for 70' buses. Bus Depot use to sell them. I couldn't find anything other than obvious Chinese copies. I couldn't find anyone selling the VDO ones that were identical to the VDO German made ones back in the day. We're screwed..
I bought a VDO (Brazilian made) sender for my bus 3 years ago. So far, no issues and I didn't install an access hatch. If this VDO Brazilian sender shits the bed, I'll also reach for a sawzall..
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Decades of VW and VW parts restoration experience.
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**Now rebuilding throttle bodies for VW's and Porsche's**
**Restored German Bosch distributors for sale or I can restore yours**
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Xevin
Samba Member
Joined: January 08, 2014
Posts: 7624
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| Posted: Tue Oct 31, 2017 1:19 pm Post subject: Re: How to replace your fuel sending unit in your baywindow bus |
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| wcfvw69 wrote: |
I couldn't find anyone selling the VDO ones that were identical to the VDO German made ones back in the day. We're screwed..
I bought a VDO (Brazilian made) sender for my bus 3 years ago. So far, no issues and I didn't install an access hatch. If this VDO Brazilian sender shits the bed, I'll also reach for a sawzall.. |
Put down the sawzall Bill Telfords got you covered 
https://www.thesamba.com/vw/forum/viewtopic.php?t=...mp;start=0
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Keep on Busin'
| 67rustavenger wrote: |
| GFY's Xevin and VW_Jimbo! |
| Clatter wrote: |
| Damn that Xevin... |
| skills@eurocarsplus wrote: |
| I respect Xevin and he's a turd |
| SGKent wrote: |
| My God! Xevin and I 100% agree |
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alman72
Samba Member
Joined: October 09, 2014
Posts: 2573
Location: MICHIGAN
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| Posted: Tue Oct 31, 2017 1:30 pm Post subject: Re: How to replace your fuel sending unit in your baywindow bus |
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I like Skills plate. almost invisible. that has to be a donor piece out of another bus?
I would really love to get my hands on the VW plate pictured above. Was that plate used in any other VWs, or stamped out just for the bus fix? |
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wcfvw69
Samba Purist
Joined: June 10, 2004
Posts: 13389
Location: Arizona
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| Posted: Tue Oct 31, 2017 1:50 pm Post subject: Re: How to replace your fuel sending unit in your baywindow bus |
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| Xevin wrote: |
| wcfvw69 wrote: |
I couldn't find anyone selling the VDO ones that were identical to the VDO German made ones back in the day. We're screwed..
I bought a VDO (Brazilian made) sender for my bus 3 years ago. So far, no issues and I didn't install an access hatch. If this VDO Brazilian sender shits the bed, I'll also reach for a sawzall.. |
Put down the sawzall Bill Telfords got you covered
https://www.thesamba.com/vw/forum/viewtopic.php?t=...mp;start=0 |
I've seen that wonderful thread and repair. The issue is getting to the sender again if need be! 
I'd so pull this bitch out and go for it! 
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Follow me on instagram @sparxwerksllc
Decades of VW and VW parts restoration experience.
The Samba member since 2004.
**Now rebuilding throttle bodies for VW's and Porsche's**
**Restored German Bosch distributors for sale or I can restore yours**
**Restored German Pierburg fuel pumps for sale or I can restore yours**
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Wildthings
Samba Member
Joined: March 13, 2005
Posts: 50337
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| Posted: Tue Oct 31, 2017 2:45 pm Post subject: Re: How to replace your fuel sending unit in your baywindow bus |
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| alman72 wrote: |
I like Skills plate. almost invisible. that has to be a donor piece out of another bus?
I would really love to get my hands on the VW plate pictured above. Was that plate used in any other VWs, or stamped out just for the bus fix? |
Type 4 cars had a variety of plates under the carpets, don't know about other VW vehicles. That said, a larger hole than VW recommends makes accessing the sender easier. I like making the hole using a 1" +/- hole saw to cut rounded corners and then a reciprocating saw to make straight lines connecting the corners. The straight sides of the cut give better purchase when trying to twist the sender out with a screwdriver or bar. |
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skills@eurocarsplus
Samba Peckerhead
Joined: January 01, 2007
Posts: 16863
Location: sticksville, ct.
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| Posted: Tue Oct 31, 2017 4:28 pm Post subject: Re: How to replace your fuel sending unit in your baywindow bus |
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| alman72 wrote: |
I like Skills plate. almost invisible. that has to be a donor piece out of another bus?
I would really love to get my hands on the VW plate pictured above. Was that plate used in any other VWs, or stamped out just for the bus fix? |
donor bus is what I made my plate from
on my post here:
https://www.thesamba.com/vw/forum/viewtopic.php?p=8598245#8598245
you can see how badly it was done...and way off center too. as WT points out, it's still too small, but in my case it was done so badly, you *may* be able to do it with that plate, but you would have to cut it about to the edge of the thing.
_________________
| gprudenciop wrote: |
my reason for switching to subaru is my german car was turning chinese so i said fuck it and went japanese....... |
| Jake Raby wrote: |
| Thanks for the correction. I used to be a nice guy, then I ruined it by exposing myself to the public. |
| Brian wrote: |
| Also the fact that people are agreeing with Skills, it's a turn of events for samba history |
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airschooled
Air-Schooled
Joined: April 04, 2012
Posts: 12721
Location: on a bike ride somewhere
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| Posted: Tue Oct 31, 2017 5:55 pm Post subject: Re: How to replace your fuel sending unit in your baywindow bus |
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| Xevin wrote: |
| wcfvw69 wrote: |
I couldn't find anyone selling the VDO ones that were identical to the VDO German made ones back in the day. We're screwed..
I bought a VDO (Brazilian made) sender for my bus 3 years ago. So far, no issues and I didn't install an access hatch. If this VDO Brazilian sender shits the bed, I'll also reach for a sawzall.. |
Put down the sawzall Bill Telfords got you covered
https://www.thesamba.com/vw/forum/viewtopic.php?t=...mp;start=0 |
I just ran that procedure on a Type 3 with a corroded fuel sender but only 32,000 original miles on the clock. It was the first time the owner had ever seen the gauge work, and it is dead nuts accurate now.
My problem is, the floats of the new Chinese senders sink after a year in fuel. So no amount of soldering will improve my situation. Sawzall comes out sometime soon, I suppose.
Robbie
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fes
Samba Member
Joined: January 26, 2011
Posts: 999
Location: Prince Edward Island
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| Posted: Tue Oct 31, 2017 6:28 pm Post subject: Re: How to replace your fuel sending unit in your baywindow bus |
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This is the piece of shit chinafied sender I received..(notice the internal wire dangling with it's dick in the wind)
My replacement gave up the ghost a year later..damn garbage
Now I just use my my mileage as as my fuel gauge until I get around to rebuilding my OG sending unit
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busdaddy
Samba Member
Joined: February 12, 2004
Posts: 51125
Location: Surrey B.C. Canada, but thinking of Ukraine
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| Posted: Tue Oct 31, 2017 6:52 pm Post subject: Re: How to replace your fuel sending unit in your baywindow bus |
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| fes wrote: |
| .... until I get around to rebuilding my OG sending unit |
Do it!, it's the last sender you'll ever need.
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wcfvw69
Samba Purist
Joined: June 10, 2004
Posts: 13389
Location: Arizona
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| Posted: Tue Oct 31, 2017 7:45 pm Post subject: Re: How to replace your fuel sending unit in your baywindow bus |
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| asiab3 wrote: |
| Xevin wrote: |
| wcfvw69 wrote: |
I couldn't find anyone selling the VDO ones that were identical to the VDO German made ones back in the day. We're screwed..
I bought a VDO (Brazilian made) sender for my bus 3 years ago. So far, no issues and I didn't install an access hatch. If this VDO Brazilian sender shits the bed, I'll also reach for a sawzall.. |
Put down the sawzall Bill Telfords got you covered
https://www.thesamba.com/vw/forum/viewtopic.php?t=...mp;start=0 |
I just ran that procedure on a Type 3 with a corroded fuel sender but only 32,000 original miles on the clock. It was the first time the owner had ever seen the gauge work, and it is dead nuts accurate now.
My problem is, the floats of the new Chinese senders sink after a year in fuel. So no amount of soldering will improve my situation. Sawzall comes out sometime soon, I suppose.
Robbie |
Maybe it's time to start checking for some original German VDO senders at the swaps. Refurbish them for a spare or two.
_________________
Contact me at [email protected]
Follow me on instagram @sparxwerksllc
Decades of VW and VW parts restoration experience.
The Samba member since 2004.
**Now rebuilding throttle bodies for VW's and Porsche's**
**Restored German Bosch distributors for sale or I can restore yours**
**Restored German Pierburg fuel pumps for sale or I can restore yours**
**Restored Porsche fuel pumps or I can restore yours**
**Restored Porsche distributors or I can restore yours** |
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skills@eurocarsplus
Samba Peckerhead
Joined: January 01, 2007
Posts: 16863
Location: sticksville, ct.
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| Posted: Tue Oct 31, 2017 8:00 pm Post subject: Re: How to replace your fuel sending unit in your baywindow bus |
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| wcfvw69 wrote: |
Maybe it's time to start checking for some original German VDO senders at the swaps. Refurbish them for a spare or two. |
don't bother
if they haven't had the float pinned, the wire will be trashed. ask me how I know 
unless you want to gamble...
_________________
| gprudenciop wrote: |
my reason for switching to subaru is my german car was turning chinese so i said fuck it and went japanese....... |
| Jake Raby wrote: |
| Thanks for the correction. I used to be a nice guy, then I ruined it by exposing myself to the public. |
| Brian wrote: |
| Also the fact that people are agreeing with Skills, it's a turn of events for samba history |
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