Date:         Tue, 24 Sep 2002 20:52:17 -0400
Reply-To:     dxrobertson@NETSCAPE.NET
Sender:       Vanagon Mailing List <vanagon@gerry.vanagon.com>
From:         David Robertson <dxrobertson@NETSCAPE.NET>
Subject:      gas filler neck leak
Content-Type: text/plain; charset=iso-8859-1

82 air cooled gas vanagon.  severe leak around bottom of filler neck to tank connection.



History-

PO had replaced gas tank with what as far as i know is a typical aftermarket tank. Tank has the original larger sized filler hole (70mm or whatever) that matches the original filler neck parts.  Filler neck and all associated parts were not replaced with new (except tank grommet) and they all appear to be ok.  All the top grommets and lines were properly replaced and are fine.  There is a severe leak around the filler neck, at the bottom.  As I fill the tank with gas, once the gas level reaches the bottom of the filler neck; it shoots and runs out from around the filler neck to tank connection.

I have searched the archives and havent found an exact answer to this problem.  What I did find was a post in regards to the critical alignment of the filler neck to the tank.  I believe this to be the cause of the leak.

With the filler neck removed, I look through the hole in the frame member and notice the tank hole is about 1/4 inch lower than the frame hole.  Looks to me that the tank is too low and the filler neck is "resting" on the frame member and thus pushed up as it enters the filler hole in the tank, thus leaving a gap around the bottom of the neck to tank connection.  I also notice that looking at the side of the tank lip, below around where the filler neck is; that the tank lip is not snug up against the bottom of the frame member, but site about a 1/4 inch below.  I tried to "raise" the tank by inserting some rubber shims between the brace that holds up the tank on that side, and the tank, but all that did was start to indent the tank at that point.  It seems like the tank is binding somewhere and not able to mount in its "up-most", up against the frame position (if it is indeed supposed to be up against the frame).

My questions-
What is causing what I think is an extreme gap at the bottom of my filler neck to tank connection?

assuming this is an alignment problem; Is the top of the tank lip supposed to be snug up to the bottom of the frame member?  Where would I "raise" the tank to make its lip snug with the frame member?  Perhaps I need to "force" (unbind whatever is binding it) the tank up so that the lip is snug against the bottom of the frame?

Any other ideas or something to try?

As a VERY last resort, assuming I cant make the proper alignment; what would be an appropriate filler compound to use around the filler neck to tank conection in an attempt to seal the leak?  The PO used silcone, but this melted once it encountered gas.



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