In the middle of fuel tank extraction...

[lloydy]

The feed pipe runs across the top of the tank, could just be that? Could be easy to replace, connect new pipe to old and pull it through? Although as it's a syncro, will probably be plenty of reasons why it's not that simple

[ninja.turtle007]

Where does it run from and go to?

[lloydy]

It comes out the bottom of tank through big hole in tank strap

Mine then runs past the sender unit on side of tank and then up and over tank, then comes out in engine bay and connects to filter

[ninja.turtle007]

Thanks. I'll have a look later. Fingers crossed!

[silverbullet]

Tom,
I removed my gearbox in 6 1/2 hours from putting it up on ramps; never done one before but 20 years of old car tinkering experience must count for something. I had relatively recently fitted the engine protection bars, so it all came apart easily. Removing the tank probably took another 3 to 4 hours, allowing for dirt in eyes, finding out what was still in the way or snagged and the like...
I had been told that this was a good time for a first-time 'box removal and I did get lucky in that everything undid, bar the odd clip or screw that had to be cut off (and 3 stripped out cv bolts - cutting disc time)
I'll take a pic of the breather hose arrangement for the wiki, as mine seems to be all original. I don't think they are realistically accessible without dropping the tank.
Give yourself a full weekend to get it all out with prep on a Friday night. Once all out you can then see how much rust there is to deal with, like mine
Waiting for an ebayer to collect then it's overalls on for some more de-rusting...

[ninja.turtle007]

Tom,
I removed my gearbox in 6 1/2 hours from putting it up on ramps; never done one before but 20 years of old car tinkering experience must count for something. I had relatively recently fitted the engine protection bars, so it all came apart easily. Removing the tank probably took another 3 to 4 hours, allowing for dirt in eyes, finding out what was still in the way or snagged and the like...
I had been told that this was a good time for a first-time 'box removal and I did get lucky in that everything undid, bar the odd clip or screw that had to be cut off (and 3 stripped out cv bolts - cutting disc time)
I'll take a pic of the breather hose arrangement for the wiki, as mine seems to be all original. I don't think they are realistically accessible without dropping the tank.
Give yourself a full weekend to get it all out with prep on a Friday night. Once all out you can then see how much rust there is to deal with, like mine
Waiting for an ebayer to collect then it's overalls on for some more de-rusting...

Hopefully it won't come to that. If it does I'll drop it over to you for the weekend!! Tomorrow I'm going to test the pipe Lloyd mentioned. I think he might be right. If he is and I can't pull it through I can't see why I can't route it a different way.

[silverbullet]

You're welcome to come round and have a look at what's involved if you want to see one in bits Tom! I reckon I'd do another one now that I know what's involved and if I had the driveway space - bit full up here, as those who know Bullet Towers can testify
Weekend to get it out, another to get it all scrubbed up and treated/painted and another to get it all back in. That's if nothing is broken or found to be rotten and the job goes well generally...a big ask for a syncro

[axeman]

i managed to remove the engine and the gearbox with a friend (paul has no vw experience) in about three and a half hours, doing everything with sympathy so it can all be re used. the tank took a further 3 hours to fettle out, it was a real bugger to do. as ian said if you want to pop over and have a look i am a little closer to you.

neil

[silverbullet]

Probably easier and quicker to pull the whole engine and box as one unit like Neil's done. My engine stayed put (it's healthy) and I left the coolant pipes connected. They do spring out of the way to let the tank finally drop out but you can reclon on cutting all the fuel hoses and replacing the lot as the breather pipes will be at least 19 years old now

[ninja.turtle007]

Thanks guys. Leak has stopped?? Still going to replace the feed pile as I bought a length yesterday. Managed to shear the bottom of the drop link changing the front cv gator.