After getting advice from the board I had 3 different methods to try for getting
the fuel pump out of it's cave. The return line is not easily removed from the metal line coming out of the tank and makes it "interesting" to pull the works out of the tank through the access hole in the deck of the car. So I had the these suggestions.....
1) Cut the return line and splice a new length of fuel line in.
2) Heat up the return line and push it off the barbed metal line.
3) Pull the return line up and out (after disconnecting it at the junction).
I opted to try pulling the line up and out and with a little pulling and twisting it came right up. I now have the whole works on my bench. Found that
the rubber (bellows looking) in tank hose had split. So while the in tank pump
is working, it wasnt able to push gas up the metal line to the external pump.. it was just kind of free wheeling in there. Explains the cycling sound the external pump was making. (the old one died and I just put a new external pump/filter in).
But you could hear it cycle up an down (speed).
Now I think I will use the other suggestions.. but after the fact. Now that it
is on my bench I will heat up the return line and remove it from the metal line and cut off 3/4" or so where it is deformed from being on the metal line. I plan on
installing a 4" or so piece of fuel line on the end of this hose (hose clamped) so when I reinstall the works into the tank I dont have to fight the hose also. Doing
all this on the bench is easier than doing it while it was in the hole!
progress pics are being taken and will be posted along with the others I have up so far. This isnt as bad as I thought it might be and with the pics to look at hopefully it will make it easier for the next person to tackle this job.
Many thanks to everyone who has taken the time to give advice!
stay tuned ;-)
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vw bus site - http://www.geocities.com/vw_bus_74/index.html