Broken rollover valve on gas tank - $2500!
03-15-2013, 05:59 AM
#11
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That's an interesting option that a neighbor of mine actually suggested. I've decided to fork out the $109 for the diagnostic to take it back to customer service and see what happens. If nothing then I'm down to the trap door solution you mention or packing it in.
03-15-2013, 06:14 AM
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I did a quick search but couldn't find. I'll look again. I did find this nice post (w/ pictures) that shows a broken valve someone else repaired with epoxy. My borken valve is the one with a blue circle in his picture. I'm not real keen on this solution as I not sure it addresses the issue & I would think would be prone to happening again.
http://forums.quattroworld.com/allroad/msgs/89963.phtml
http://forums.quattroworld.com/allroad/msgs/89963.phtml
http://www.tech-bond.net/Product_Home_Pagel.html
I repaired a hole in the gas tank overflow on my A6 with Tech-Bond and it works. Made a patch out of a jug and bonded it and you can't remove it once it's set. I have also used the soldering iron trick on broken tabs on various interior trim pieces using a plastic swizzle stick as welding rod.
If you can gain access to the affected area you'll be set. I think cutting an access hole might be the way to go but I'm not familiar with the geography of the tank relative to the under side of the body.
You might just be stuck going the dealer route. OUCH!
03-15-2013, 02:30 PM
#14
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Long story but here's the cliff note version. Recently I filled up my tank and after doing so had a very strong smell of gas in the cabin. I took it to an independent mechanic and he told me that I have a broken rollover valve. The rollover valve is located on the top of the tank on the front driver side. To fix it will cost $2500 ($1500 for the tank and $1000 for labor). I've already validated from several sources this cost is accurate. It is a 10+ hour job as the tank sits on top of the wheel assembly. If the cost isn't enough of a stinker I found out there is a recall to reinforce the valve with epoxy bond. So this was a known potential problem! Unfortunately the recall is for 2001-2004 models and mine is a 2000. I've been told that the 2000 has the exact same tank/valve so why car wasn't included is unknown (I've asked Audi and just get run around answers). I next contacted Audi customer service to get a case # established in hope that they'd take some kind of responsibility. They created the case but told me until the issue is verified by an Audi dealer that they can't do anything. I asked if I do that and that the dealer verifies the issue what I can expect. They told me there are no guarantees. This is point of contention #2 (#1 being excluded from the recall). Why can't they tell me what might be done IF the dealer validates the issue? So, I called the dealer and they said they might be able to identify the issue with a boroscope which will cost $109 + tax. If they can't they'd need to drop the assembly to get to the tank. If it comes to dropping the assembly then I'm out. The labor to do so would be costly with no guarantees that anything would come of it.
So...my questions to my esteemed Audi owners are:
1) Would you spend another $109+ just to take it back to Audi Customer Service and see what they might do? If I don't I'd have to call it quits and sell my beloved Audi, get a new car and deal with car payments. I don't want to invest $2500 into a 13 year old car. The repair is more than the blue book.
2) Do I have any other options/recourse?
P.S. If it matters the car has been well maintained, has no other known issues and has 169,000 miles.
Thanks for all the advice/input.
So...my questions to my esteemed Audi owners are:
1) Would you spend another $109+ just to take it back to Audi Customer Service and see what they might do? If I don't I'd have to call it quits and sell my beloved Audi, get a new car and deal with car payments. I don't want to invest $2500 into a 13 year old car. The repair is more than the blue book.
2) Do I have any other options/recourse?
P.S. If it matters the car has been well maintained, has no other known issues and has 169,000 miles.
Thanks for all the advice/input.
03-18-2013, 01:15 PM
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Update: The dealership called today and confirmed the issue first identified by the independent. Cost to patch is $452+tax. This is the same resolution suggested by the recall which is to bond/epoxy the valve joint. They told me to expect a call from AoA as they just got off the phone with them and were told AoA would not be chipping in. AoA called shortly after and gave me the news with the main reason being that the car has 169k miles and a secondary reason being that I had stopped taking it to the Audi dealership (so they don't know how well the car has been cared). I really understand, and expected, this but still don't agree. If my car was a 2001 with 300k miles would they not have sent me the recall notice? Regardless of mileage this is a known design fault that Audi has acknowledged. My 2000 has the exact same issue to a "T" that they are addressing with the 2001-2004 models (again...regardless of mileage). The dealership (not AoA) did offer a 15% discount so my cost would be $384+tax. As much as I don't want to sink more money into the car I think this is an amount I'm willing to go for rather than take on new car payments and hope I'm not hit with another costly repair over the next few months.
SloopJohn, I absolutely will file a case with NHTSA. I don't expect anything to come of it but it can't hurt.
SloopJohn, I absolutely will file a case with NHTSA. I don't expect anything to come of it but it can't hurt.
03-18-2013, 01:25 PM
#17
AudiWorld Super User
Update: The dealership called today and confirmed the issue first identified by the independent. Cost to patch is $452+tax. This is the same resolution suggested by the recall which is to bond/epoxy the valve joint. They told me to expect a call from AoA as they just got off the phone with them and were told AoA would not be chipping in. AoA called shortly after and gave me the news with the main reason being that the car has 169k miles and a secondary reason being that I had stopped taking it to the Audi dealership (so they don't know how well the car has been cared). I really understand, and expected, this but still don't agree. If my car was a 2001 with 300k miles would they not have sent me the recall notice? Regardless of mileage this is a known design fault that Audi has acknowledged. My 2000 has the exact same issue to a "T" that they are addressing with the 2001-2004 models (again...regardless of mileage). The dealership (not AoA) did offer a 15% discount so my cost would be $384+tax. As much as I don't want to sink more money into the car I think this is an amount I'm willing to go for rather than take on new car payments and hope I'm not hit with another costly repair over the next few months.
SloopJohn, I absolutely will file a case with NHTSA. I don't expect anything to come of it but it can't hurt.
SloopJohn, I absolutely will file a case with NHTSA. I don't expect anything to come of it but it can't hurt.
This is a cheap fix as things go!
Enjoy the car.
03-18-2013, 01:33 PM
#18
AudiWorld Super User
Update: The dealership called today and confirmed the issue first identified by the independent. Cost to patch is $452+tax. This is the same resolution suggested by the recall which is to bond/epoxy the valve joint. They told me to expect a call from AoA as they just got off the phone with them and were told AoA would not be chipping in. AoA called shortly after and gave me the news with the main reason being that the car has 169k miles and a secondary reason being that I had stopped taking it to the Audi dealership (so they don't know how well the car has been cared). I really understand, and expected, this but still don't agree. If my car was a 2001 with 300k miles would they not have sent me the recall notice? Regardless of mileage this is a known design fault that Audi has acknowledged. My 2000 has the exact same issue to a "T" that they are addressing with the 2001-2004 models (again...regardless of mileage). The dealership (not AoA) did offer a 15% discount so my cost would be $384+tax. As much as I don't want to sink more money into the car I think this is an amount I'm willing to go for rather than take on new car payments and hope I'm not hit with another costly repair over the next few months.
SloopJohn, I absolutely will file a case with NHTSA. I don't expect anything to come of it but it can't hurt.
SloopJohn, I absolutely will file a case with NHTSA. I don't expect anything to come of it but it can't hurt.
but i agree get the fix done ... cheaper than car payments. thats about the only job where you cant do any while you're in there projects too.
10-11-2013, 11:45 AM
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This is an old post but I thought I'd update with the latest news in case someone else with a similar problem stumbles across this thread.
I had the epoxy patch done in March for a cost of $375. Earlier this week (October) I filled up the tank and the tell tale symptom of gas in the cabin is back. This is under warranty for 12 months or 12k miles so I took it to the dealership and they confirmed it is the same issue as last time but that they could not patch it again. To do so they'd need to get the old epoxy off and in doing so they say will rip the valve off causing a larger issue. They said the only resolution now is to replace the tank for $3,000. The statement that the patch was under warranty is really a snow job since they know that it can't be re-applied a second time.
My only two options left are put $3k into a 12 year old car with 172k miles or move on. Sadly I've decided to move on as that is too much money for a car this old IMO. I still claim that Audi isn't taking responsibility for this issue given that the 2001-2004 models have the EXACT same issue with the EXACT same parts but my 2000 model isn't included in the recall. I've put in all the complaints that I could and seem to have lost the good fight.
P.S. The dealership told me that I could keep driving it but to only fill up the tank to 1/2 way since the valve is at the top of the tank. While doing so seems to eliminate the smell of gas I'm thinking this is not a wise/safe option given that there is a crack in the valve allowing gas vapors to escape which are obviously flammable.
I had the epoxy patch done in March for a cost of $375. Earlier this week (October) I filled up the tank and the tell tale symptom of gas in the cabin is back. This is under warranty for 12 months or 12k miles so I took it to the dealership and they confirmed it is the same issue as last time but that they could not patch it again. To do so they'd need to get the old epoxy off and in doing so they say will rip the valve off causing a larger issue. They said the only resolution now is to replace the tank for $3,000. The statement that the patch was under warranty is really a snow job since they know that it can't be re-applied a second time.
My only two options left are put $3k into a 12 year old car with 172k miles or move on. Sadly I've decided to move on as that is too much money for a car this old IMO. I still claim that Audi isn't taking responsibility for this issue given that the 2001-2004 models have the EXACT same issue with the EXACT same parts but my 2000 model isn't included in the recall. I've put in all the complaints that I could and seem to have lost the good fight.
P.S. The dealership told me that I could keep driving it but to only fill up the tank to 1/2 way since the valve is at the top of the tank. While doing so seems to eliminate the smell of gas I'm thinking this is not a wise/safe option given that there is a crack in the valve allowing gas vapors to escape which are obviously flammable.
Last edited by rwish; 10-11-2013 at 11:54 AM.