[T3] Fuel Filler Hose leaks

[Jim Adney]

On 24 Jun 2013 at 11:48, Chris Sheridan wrote:

> I developed a sudden and rather large fuel leak in my fuel filler hose
> where the hose connects from the fuel filler tube to the gas tank, under
> the hood. I ordered a replacement hose and rubber seals to do the job. The
> replacement was straightforward, however it didn't stop the leak. 

> Is there an order of assembly that insures no leaks? I noticed that the
> Metal Fuel filler must be removed to adequately seat the rubber hose and
> gaskets without kinking them, but then when you tighten the metal filler
> back to the frame it obviously must distort the sealing surface of the
> rubber hose connection.

I have always done this job without loosening the filler pipe, but I 
agree that it's likely that the filler pipe was installed at the 
factory after the gas tank and hose were in place and before the 
fenders were installed.

This is a VERY hard job to do right, without causing the rubber seal 
rings to slip out of place, and it's compounded by the fact that you 
can't see the underside to inspect your work.

I would slip the seal rings onto the tubes, then lightly oil their 
outside faces. A little oil on the inside of the hose and then slip 
them together. (Yes, easier said than done.)

If you're willing to disconnect the filler pipe, just slide it back a 
bit, slip the hose onto the tank, and then slip the filler pipe back 
into place while inserting it in the hose. Don't tighten any hose 
clamps until everything else is tightened in place and you've 
inspected the seals (use a small mirror) to make sure they're in 
place.

> Is there a source for the original type of hose clamps or are we stuck with
> the regular common ones?

I've always reused the OE clamps. They do NOT have to be all that 
tight; they just have to be tight enough. I might have some if yours 
are no longer usable. It's possible that you've overtightened the 
common worm gear clamps enough to distort the tube underneath, and 
that may be the cause of your problem.

Note that early '68s had an oval entrance pipe to the gas tank. That 
oval pipe was MUCH harder to seal, because you couldn't get any 
sealing force against the flat sides of the oval. That was something 
VW fixed rather quickly, with the round entrance pipe.

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Jim Adney, jadney at vwtype3.org
Madison, Wisconsin, USA
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