I just did this (again) a couple of weeks ago.

I did the reseal using the Van Cafe kit three years back, but didn't
replace the fuel gauge sender or, more importantly, the O-ring that seals
it to the tank.  Recently a massive leak developed there, and even if I
filled up 3/4 full you could still smell gas around the driver's side.  On
full fill-ups, gas would visibly leak down from the sender area.  I also
have been fighting the buzzing fuel pump issue since I bought this
particular Vanagon almost eight years ago.

This time around, I decided to bite the bullet and go with the newer-style
tank with the larger outlet to the fuel pump, discard the plastic
pre-filter in favor of the big metal cylindrical after-pump filter, and
replace the sending unit and its o-ring completely.

I have to say that this is what I should have done last time.  The only
issue I had was getting the new sender into the new tank.  It was a bear to
get in, and I ended up shattering it into three pieces by trying to muscle
it too much with a big wrench.

Thankfully, there was nothing wrong with my old sender, and with a new
o-ring, it went in fine.  Although it sucks to watch fifty bucks shatter
into three pieces...

I'm happy to report no constant gas smell, full fill-ups, and a nearly
inaudible fuel pump.

>
> --
> Joe T.
> '85 Wolfsburg Westy Subie 2.2

On Mon, Mar 11, 2013 at 1:54 PM, Scott Daniel - Turbovans <
scottdaniel@turbovans.com> wrote:

> If one jacks up the van ..
> and looks in there at the top of the tank, one can often see the broken
> cross-over plastic T's.
> Front tires off helps.
> It is even possible, but difificul, t to repair those with tank in place.
>
> most opt for pulling the tank, doing 'the whole job right' ..
> buy a reseal kit from Van Cafe etc.
>
> if you have an 84 with the large metal filler neck ...
> let's just say the later smaller plastic filler neck is about 4 times
> easier to deal with , especially going back together.
> Like if you replace the large filler neck tank..
> buy one with for the smaller filler neck hole and then buy a used
> plastic filler neck. It's so much easier to work on that way.
>
> sdf
>
>
>
>
>>>>> --
>>>>> Joe T.
>>>>> '85 Wolfsburg Westy Subie 2.2
>>>>
>>>>