I'm looking for ideas on repairing the sending and return lines from the tank to fuel filter.
I can't break the joints loose and was thinking of cutting metal lines and running rubber to replace.
What is the pressure in the supply line?
Will rubber line and hose clamps hold?
Also, can't get the push-on connection disconnected at the sending unit.
The car is a '94 940 wagon, non-Regina, in the rust belt upstate NY area

 

I wouldn't use rubber lines, too hard to get to clamp to soild fuel line without a proper formed end, and you don't want a massive fuel leak as you drive along....
I'd probably try and btain some new fuel lines from an out of state car (or at least out of rust belt) and give them a good coating of something to prevent future rust.
You could hand form steel lines, but it's a painful process.

Regards, Andrew.

 

Thanks Andrew. I was hoping to avoid that.

 

I understand why you are trying to avoid it, it's a bit of work. Sometimes though, the correct repair is the only one you should consider.
Another option may be to find some sort of compression tightening fitting that will fit over the remaining good steel line and use some high pressure EFI hose off that.
But, it's going to be painful cutting the existing line neatly enough to use this fix under teh car, and if you do use rubber line, you relaly should make a shield for it (to protect from damage when bottoming out etc).

Regards, Andrew.