Indeed I noticed the cracked plastic hole might allow dirt in the tank. I would like to just plug the hole but realize this might cause issues as well till spring.

I would like to find an easy way to just possibly place some fuel hose within the existing cracked plastic and then attach that to the existing crossover tube I got from Ken. It's freezing cold outside and I don't have a heated garage so this is major problem for me.

I did some samba research, indeed there are vendors such as Go Westy, Bus Depot and Van Cafe that sell $100+ kits with nice aluminum connectors.

Anyone have any tips on how to not drop the tank and patch this single cracked Y connector?

On Jan 4, 2012, at 12:34 AM, Dennis Haynes wrote:

> This is a very common problem. You need the top crossover tube. There are
> some vendors that sell a much improved set up with aluminum fittings. Not
> only can gas or fumes get out but road dirt and water can get in.
>
> Dennis
>
> -----Original Message-----
> From: Vanagon Mailing List [mailto:vanagon@gerry.vanagon.com] On Behalf Of
> Robert Stewart
> Sent: Tuesday, January 03, 2012 3:28 PM
> To: vanagon@GERRY.VANAGON.COM
> Subject: Re: Gas Vapors
>
> I found the source to my gas smelling issue.
>
> On the top center of the tank under the van I was able to take my iphone and
> make a movie with the flash on and I can see in the center that there was a
> Plastic Y that appears to have broken off at the lower base of the Y
> connector and now only the top part of the Y is connecting the hoses which I
> believe go to the vapor recovery system.
>
> What is the part needed to replace that broken unit? In the meantime Can I
> put something in the hole to prevent the leaks and smells?
>
> Thanks,
> Robert
> Bloomingburg NY
>
> On May 29, 2011, at 4:51 PM, Scott Daniel - Turbovans wrote:
>
>> it's a very unfun job.
>> hour or two  max to get out.
>>
>> it's just fiddly.
>> not like you can bolt one part on, then the next, then the next etc.
>>
>> it's like you need it floating nearly in place while you mess with the
> hoses
>> and wires n' stuff on top of it.
>> Like on a floor jack 'up there' almost where it goes, while you disconnect
>> or connect stuff.
>>
>> they didn't want that to be too easy a job evidently.
>>
>> pretty sure you are 2WD ..the Syncro is a whole other story.
>>
>> and if it's an early 2WD van with the larger metal filler neck..
>> those can be a real PIA to get back in place at the bronze collar by the
> gas
>> cap getting small screws started in the bronze piece while they are
> sticking
>> through another rubber piece....yuck.
>> The later plastic filler neck is very easy to deal with.
>>
>> ----- Original Message -----
>> From: "Robert Stewart" <robertmstewart@MAC.COM>
>> To: <vanagon@GERRY.VANAGON.COM>
>> Sent: Sunday, May 29, 2011 12:06 PM
>> Subject: Re: Gas Vapors
>>
>>
>>> Thanks John,
>>>
>>> This might be the case with my van as well.  Any idea how hard it is to
>>> drop the tank and replace the seal? How long does it take?
>>>
>>> Rob
>>> NY
>>>
>>> On May 28, 2011, at 9:44 PM, John Jensen wrote:
>>>
>>>> Not sure if this is any help, but I had a problem when the gasket where
>>>> the filler pipe goes into the tank went bad,  Leaked on
>>>> turns and when I filled the tank.  I set out to replace the whole tank
>>>> and discovered the bad gasket in the process.  In that case it was a
>>>> 1982 air-cooled vanagon.
>>>>
>>>> John Jensen
>>>> johnjensen@johnjensenartist.com
>>>> http://www.johnjensenartist.com
>>>> bluesbug@verizon.net
>>>>
>>>>
>>>> On 5/28/2011 1:43 PM, Dennis Haynes wrote:
>>>>> With some effort and flashlight you can check for broken tube fittings
>>>>> without dropping the tank. It is also possible the leak is from the
>>>>> gauge sender o ring especially on the aftermarket tanks.
>>>>>
>>>>> Dennis
>>>>>
>>>>> Sent from my Windows Phone
>>>>>
>>>>> -----Original Message-----
>>>>> From: Robert Stewart
>>>>> Sent: Saturday, May 28, 2011 3:33 AM
>>>>> To: vanagon@GERRY.VANAGON.COM
>>>>> Subject: Re: Gas Vapors
>>>>>
>>>>>
>>>>>
>>>>>> I noticed today where the fuel smell is coming from. Just under my
> seat
>>>>>> where the tank under me I saw today a small amount gas that appears to
>>>>>> have leaked out of some hose! I made a really sharp fast turn and I
> saw
>>>>>> a couple of tiny drips on the ground of the driveway that traced my
>>>>>> turning radius. Sure enough I can see it's dripping from the top of
> the
>>>>>> tank down to the ground.
>>>>>>
>>>>>> Does this mean that either the plastic crossover is cracked or that
>>>>>> another hose is cracked or finally does it mean the cross over tube
>>>>>> came out from the top of the tanks mounts?
>>>>>>
>>>>>> Note, I changed this entire tank 4 years ago with a new tank that I
>>>>>> covered with Herculiner to prevent rusting and it looks amazing still.
>>>>>> Plus over a year ago I installed a new set of fuel lines and a new
> seal
>>>>>> and crossover kit.
>>>>>>
>>>>>> So I am a little surprised.
>>>>>>
>>>>>> Robert
>>>>>> NY
>>>>>>
>>>>>> On May 25, 2011, at 11:20 PM, Robert Stewart wrote:
>>>>>>
>>>>>>> Dennis,
>>>>>>>
>>>>>>> I looked tonight at my air filter, there is a line coming from the
> top
>>>>>>> of the round filter that has been capped off. Isn't this suppose to
>>>>>>> connect to the charcoal filter? Where is that suppose to go? I assume
>>>>>>> I should connect that properly correct? I think a VW mechanic I used
>>>>>>> in Long Beach NY put a ball bearing in it and capped it off.
>>>>>>>
>>>>>>> Rob
>>>>>>>
>>>>>>> On May 22, 2011, at 7:21 PM, Dennis Haynes wrote:
>>>>>>>
>>>>>>>> From: Robert Stewart [mailto:robertmstewart@mac.com]
>>>>>>>> Sent: Sunday, May 22, 2011 7:09 PM
>>>>>>>> To: Dennis Haynes
>>>>>>>> Cc: vanagon@GERRY.VANAGON.COM
>>>>>>>> Subject: Re: Gas Vapors
>>>>>>>>
>>>>>>>>
>>>>>>>>
>>>>>>>> I can't speak as to the Black Silicone looking thing he used on the
>>>>>>>> seals.
>>>>>>>> But I do believe it said it was ok for gas. Not sure.
>>>>>>>>
>>>>>>>>
>>>>>>>>
>>>>>>>> Gravity Valves are where?
>>>>>>>>
>>>>>>>> On top of each tank in the wheel wells.
>>>>>>>>
>>>>>>>>
>>>>>>>>
>>>>>>>> Vapor Recovery valve is on the left, right front or behind the air
>>>>>>>> filter?
>>>>>>>> What should I do with it once I locate it?
>>>>>>>>
>>>>>>>> In front of the air filter on the other side of the firewall. You
>>>>>>>> should be
>>>>>>>> able to hear it click each time the throttle is opened when the
>>>>>>>> engine is
>>>>>>>> running.
>>>>>>>>
>>>>>>>>
>>>>>>>>
>>>>>>>> I never have heard any pressure release sounds coming from the gas
>>>>>>>> tank cap
>>>>>>>> and this is my second van, so what is missing?
>>>>>>>>
>>>>>>>> Something is leaking somewhere. Just think later cars will generate
> a
>>>>>>>> fault
>>>>>>>> code when the tank can't hold vapor pressure.
>>>>>>>>
>>>>>>>>
>>>>>>>>
>>>>>>>> Thanks,
>>>>>>>>
>>>>>>>> Robert
>>>>>>>>
>>>>>>>>
>>>>>>>>
>>>>>>>> On May 22, 2011, at 6:58 PM, Dennis Haynes wrote:
>>>>>>>>
>>>>>>>>
>>>>>>>>
>>>>>>>>
>>>>>>>>
>>>>>>>> Silicon and gasoline. What was someone thinking. Most say on the
> tube
>>>>>>>> not
>>>>>>>> for use with gasoline or on head gaskets. It could just be a loose
>>>>>>>> hose or
>>>>>>>> one of the gravity valves on top of the expansion tanks. Also check
>>>>>>>> the
>>>>>>>> operation of the vapor  recovery valve near the air filter. If all
> is
>>>>>>>> well
>>>>>>>> whenever you open the cap for filling you should hear some pressure
>>>>>>>> escaping. After repairs the tank and vent system can be charged to
>>>>>>>> 2-3 psi
>>>>>>>> to make sure the vapors are kept in.
>>>>>>>>
>>>>>>>> Dennis
>>>>>>>>
>>>>>>>>
>>>>>>>> -----Original Message-----
>>>>>>>> From: Vanagon Mailing List [mailto:vanagon@gerry.vanagon.com] On
>>>>>>>> Behalf Of
>>>>>>>> Robert Stewart
>>>>>>>> Sent: Sunday, May 22, 2011 6:06 PM
>>>>>>>> To: vanagon@GERRY.VANAGON.COM
>>>>>>>> Subject: Gas Vapors
>>>>>>>>
>>>>>>>> A year ago my mechanic and I removed my new gas tank and installed
>>>>>>>> the
>>>>>>>> crossover pipe and a seal kit with all the rubber grommets and
>>>>>>>> clamps. He
>>>>>>>> used some special RTV silicone on all the rubber grommets before
>>>>>>>> installing
>>>>>>>> it.
>>>>>>>>
>>>>>>>> Now it's a year later and the smell of gas permeates outside the
>>>>>>>> vehicle
>>>>>>>> when I fill up. I have no idea what to do.
>>>>>>>>
>>>>>>>> I am at my wits end at this point.
>>>>>>>>
>>>>>>>>
>>>>>>>> Either a hose is damaged, or a seal must have blown ( hard to
> believe
>>>>>>>> with
>>>>>>>> the new rubber and RTV silicone though).
>>>>>>>>
>>>>>>>> Does anyone have any advice?
>>>>>>>>
>>>>>>>>
>>>>>>>> Thanks,
>>>>>>>> Robert
>>>>>>>> 88 Automatic Wolfsburg
>>>>>>>> All New Fuel Lines
>>>>>>>> All New Hoses
>>>>>>>> Rebuilt Engine
>>>>>