Petrol tank replacement (Early 1981 Aircooled)

[Lonewalker]

My van has had a petrol leak for over a year. I found out via the forum that this is common if it’s filled to the top so for the last year I’ve only filled it half full. That was fine (though a pain as the fuel gage is also inaccurate and has led to running out of petrol a few times) until a trip to Europe a few weeks ago and now it seems to leak all the time.
My question are -
- Is it an easy job to replace
- Will I need to replace everything or drop it then see what is wrong (I don’t have a garage so have to work on the street so leaving it on axel stands for weeks while I wait for things to arrive isn’t really an option)
- Apparently early vans had metal necks, should I replace this? If so there seems to be only one size 42mm though the original tank is 68mm according to Brickwerks

Sorry for all the questions but I’m not sure what order to do the work in Order then fix or strip out and then order?

Thanks in advance for any pointers.


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[Syncronorth]

My advice would be to replace everything including the fuel sender if it's very inaccurate. Also recommend this https://www.amazon.co.uk/Silverline-633 ... way&sr=8-8" onclick="window.open(this.href);return false;

https://vwt25.blog/2016/05/03/replacing ... -tank/amp/" onclick="window.open(this.href);return false;

Also one or two good videos on YouTube

I have no clue about that metal neck

[bigherb]

Yep replace the filler neck with a plastic one and use the later tank. Makes fitting the poor quality tanks easier.

[Lonewalker]

Thanks Guys.

replace the filler neck with a plastic one and use the later tank

would this be the 48mm filler version?

If so Ive seen a secondhand complete tank from a 1984 water cooled petrol van that has all pipes and sender unit attached. Would this fit?

[bigherb]

Thanks Guys.would this be the 48mm filler version?

Yes