I did this on my 84 Vanagon back in 1997, so I know it can be done. I don't remember all the details, but the main point was really to just do it. I don't remember having trouble pulling out the old line, but I do remember having a hell of a time trying to shove the new connectors into the tank.

I have a friend here in town with an 84 and her tank has the same problem. The mechanic quoted her a large sum of money to fix it and I told her that we could do it ourselves. Maybe I'll ask her to write up a summary of what we did after we do it.

In any case, here ar the details I remember:

- I took out the spare tire to get access to the area. I don't remember if this even helped at all, but I do remember it didn't help that much.

- I did not take the tires off. I think I might have turned them so I could squeeze back in for access.

- The fittings do not have hose clamps on them. I put hose clamps on the fuel line from the Y connector to the overflow tanks. I made sure I had this all set up *before* putting the Y fittings into the tank

- There are also some grommets that go between the Y fittings and the tank. These cost like $.50 at the dealer and should be replaced.

- I *think* the trick was to put the grommets into the tank first and then slowly push the Y fitting into the grommet and tank. I also put some powdered graphite on it to try and avoid pushing the grommets into the tank.

- I don't remember any difficulty at all pulling the fittings out of the tank. In any case, this should only be slightly more difficult then if you dropped the tank. They still have to come out the same way.

Good luck, blake

On Wed, 20 Mar 2002, Robert Steven Fish wrote:

> Hmmm..... > > If you say it can be done, then I will definately try it first without > dropping the tank. But it looks impossible. > > The line to the expansion tank is still OK... it is the line running over to > the next "Y-connector" on the other side of the tank that is broken. The > break is right at the base of thedrivers side "Y". > > 1. I cannot figure out how to even get this "Y-Connector" out of the > tank. I have tried to just pull and pry it a bit... but realizing that > there could be a VW special tool, or a crazy trick... I did not force it. I > have broken too many things on the cars in the past doing this... and has > always made more work for me. > > 2. The line is ripped through, and it doesn't seem like there is any hose > clamp or anything that had held the line solidly onto the "Y-connector"... > so how does one approach this? I could do a splice of some copper tubing > or something inside, and try to clamp the line side... but the connector > side is just gone. > > I will try to get the part first, take a look at it, and go from there I > guess. > > Thanks for the reply!! > > RSF > > <º)))>{ <º)))>{ <º)))>{ <º)))>{ <º)))>{ <º)))>{ > > Robert S. Fish > Salzburg, Austria > 1987 Wolfsburg Vanagon 2.1 GL Weekender > 1987 Golf Cabriolet > 1991 Golf > > ----- Original Message ----- > From: "Blake Thornton" <thornton@math.utah.edu> > To: "Robert Steven Fish" <fish@SALZBURG.CO.AT> > Sent: Wednesday, March 20, 2002 1:29 AM > Subject: Re: leaking gas when filling > > > Robert, you can do this repair without dropping the tank. It takes using > the right words of frustration as you struggle, but it is possible. > > blake > > > On Tue, 19 Mar 2002, Robert Steven Fish wrote: > > > The problem with mine is that the damn "y-connector" that is on the > drivers > > side of the top of the gas tank, has just snapped from its tube (which > runs > > over to the passenger side). It normally runs between the two plastic gas > > "overflow pressure vent" containers... there is another Y-connecter on the > > passenger side. > > > > The other day I pulled the wheel, and took a closer look at this nasty > > little tube, and I can see it, I can touch it... but there seems to be no > > way in Hell that I could do any kind of repair on it without dropping the > > gas tank. Maybe this is no big deal... but i do not really want to deal > > with it right now. > > > > I fill my tank to 3/4 full.. and no more. I am probably losing a few > > gallons a week to evaporation alone though. > > > > Hope this helps. Good Luck, > > > > RSF > > > > <º)))>{ <º)))>{ <º)))>{ <º)))>{ <º)))>{ <º)))>{ > > > > Robert S. Fish > > Salzburg, Austria > > 1987 Wolfsburg Vanagon 2.1 GL Weekender > > 1987 Golf Cabriolet > > 1991 Golf > > > > ----- Original Message ----- > > From: "Patrick Rueb" <VW87JETAGL@AOL.COM> > > To: <vanagon@GERRY.VANAGON.COM> > > Sent: Tuesday, March 19, 2002 10:42 PM > > Subject: leaking gas when filling > > > > > > > everyey time i fill my tankthe auto shut off always lets gas spill down > > the > > > side of van even if i do it maunally i never had this prob with any > other > > vw > > > any ideas no luck with water in fuse box either yet > > > thanks > > > patrick > > > 87 gon wolfs > > > > > > >