Tom,

I used to have to replace those "Y" fittings every year or two on my '84 GL,
but I have now gone about five years without a problem. A small modification
I made back then has been extremely effective in eliminating the breakage. I
took epoxy putty and molded a "ball" of it around the fittings to reinforce
the plastic. If you do this, it's necessary to be careful to leave room for
the hoses to slip over the barbed fittings. I found it impossible to do an
adequate job of this with the fittings in place due to the lack of
maneuvering room, but it's easy to do with new fittings before you install
them.

The best epoxy putty I've found can be obtained in the *plumbing* section of
Home Depot.  Look for a gold colored tube with red end caps; it contains a
"rod" of  epoxy that can be cut to length and kneaded to mix.  I believe the
manufacturer is Oatey. It's a reasonable quantity for many jobs, and costs
about five bucks.

Cliff Ober

-----Original Message-----
From: Thomas D. Hanlon <hanran.inc@INTERNETMCI.COM>
To: vanagon@VANAGON.COM <vanagon@VANAGON.COM>
Date: Tuesday, December 01, 1998 10:44 AM
Subject: Re: Fuel leak

>Steve,
>
>Across the top of the tank, at least on my 84 Westy, there is a Rube
>Goldberg arrangement of a horizontal pipe which connects to the fuel
>expansion tanks at the top of the wheel wells. Support the van so that
>the wheels drop. ( In old, dirty clothes,  you'll get filthy at this
>exercise) reach up to feel the horizontal pipe and, especially a "Y"
>connector at each end of the pipe which connects to a line to the
>expansion tank.   It is this "Y" which fails routinely in the Vanagon.
>The pipe can be replaced WITHOUT removing the gas tank, which the dealer
>will say is necessary.  ( I have done it.) The part is about $27.00 US.
>If the failed part is the Double-ended-"Y"" connector pipe, let me know
>and I'll give you the technique to replace, which involves digital
>dexterity,  removing the spare tire carrier and fiddling with the clamps
>on the pipes.
>
>Too, the cause could be the grommet at the filler pipe to the tank, or
>breaks in other small expansion lines.  If it is the filler neck
>grommet, it appears to be a tank removal job.
>
>We limped along for years by filling the tank with 10 US gallons very
>200 miles, or so.
>
>There is ample information in the archives on this topic.
>
>Tom Hanlon
>Palm Springs, CA
>1984 Westfalia
>