The shop that did mine basically hit the nuts (I thought there were 6
of them not 8) with Super Penetrant, and then repeated that multiple
times. Worked for them.

On Oct 22, 2006, at 9:37 PM, Joel Cort wrote:

> Hi guys,
>
> Apparently this can be a real painful job, if the 8 little nuts are
> rusted on the bolts.  There are 8 nuts in a round ring holding the
> sender onto the platic tank.  VW was real smart with this design:
> they integretate an internal metallic ring with 8 bolts on them
> with a rubber seal on the inside of the tank and another rubber
> seal for the outside of the tank and the sender.  The problem is
> that this 8-bolt ring is a one piece unit that was integrated into
> the fool tank. I do not think it can be removed as one piece. Yes
> you are the fool by now if you have busted one or more bolts.  If
> you are lucky you will not bust any of the bolts in the removal
> process.
>
> Seriously, the 8 little bolts pertruding out of the tank and tank
> ring are so pitted and crusty that you cannot even make that there
> are any nuts to loosen. At least here in the east where they choose
> salt to melt ice on the roads.
>
> Some of the nuts are easy to get to, but those will not be a
> problem, it is the ones behind the frame that you cannot get a grip
> on that will cause you the most anguish. Just like the CV bolts in
> the wheel well.   You will have to remove the charcoal cannister
> and the fuool filter to get to each of those crusty little
> nuts.Should you be able to wiggle the 8 crusty nuts off the
> mounting ring, the sender should be able to come straight out in
> the wheel well.
>
> The sender should be able to come out if you wiggle it and angle it
> without having to drop the fuel tank.  Should you drop the fuel
> tank then there are lots of breather hoses that you can replace
> (after you cut the damn things off).
>
> Last time I checked Van-Cafe had the sender and the rubber seals
> available.  The sender is darn pricey for what it is but hey, it is
> VW.
>
> By the way I have a spare (used) tank and the used sender that came
> with it if someone what to make me an offer.  If not, that is OK
> because I will hold on to it until my jimmied sender with
> completely fail in another 10 or 50K miles.
>
> Good luck. I can take pictures of the ring and sender parts for
> reference if need be.
> Joel
> 89 Syncro Westy
> Rochester, NY
>
>
> ----- Original Message ----
> From: Zoltan <zolo@FOXINTERNET.NET>
> To: vanagon@GERRY.VANAGON.COM
> Sent: Sunday, October 22, 2006 12:44:47 PM
> Subject: Syncro fuel sender ...
>
>
> Hi guys,
> I was wondering if any of you know the tricks to the Syncro fuel
> sender removing.  I can see, it is not as easy as the standard
> Vanagon.
> Zoltan
>
>