This has been a problem on both of my most recent Vanagons.  Some people
have made up a brass tee fitting to replace the plastic, but I managed to
repair mine. By reinforcing inside with tubing, epoxy and wrapping the
outside with tape to hold it together until the epoxy set, it made a strong,
lasting repair.  My vent and filler grommets were fine; I just cleaned and
lubed them with silcone grease. I reinstalled it all back together and it
hasn't leaked or come apart in over a year.  I found the repair kits to be
overly expensive and lacking some key pieces.  IIRC, VW no longer sells some
of the vent pieces; maybe the overflow valves?.

YMMV,

Mike B.

----- Original Message -----
From: "Allan Streib" <streib@CS.INDIANA.EDU>
To: <vanagon@GERRY.VANAGON.COM>
Sent: Tuesday, January 29, 2008 12:09 AM
Subject: Re: major fuel leak

> On Jan 28, 2008, at 9:59 PM, Allan Streib wrote:
>
>> Checked out the fuel leak situation a bit more tonight.  Tried to see
>> in across the top of the tank from the wheel wells.  Could not see
>> any obvious broken lines, and could not really reach them.  I am
>> going to try to use a hand mirror to see up there from under the
>> center of the van.
>
> Ah-ha. I did manage to get a mirror up there and the "wye" fitting on
> top of the tank on the right side is broken.  The "crossover" tube is
> dangling free with the broken end of the "wye" sticking out the end.
>
> What do you folks think of getting some brass fittings brazed in
> there, instead of the plastic wye and rubber grommets (no I won't try
> to braze a gas tank myself, I'd have that done for me).  In fact, why
> not replace the entire plastic crossover pipe with metal line?  I
> don't normally try to out-think the engineers but this looks like it
> could be better.
>
> The top of the tank looks reasonably rust-free, a few small spots
> here and there so I think chances are good that it's salvageable.
>
> Allan
> --
> 1991 Vanagon GL
>