I had the same thing happen to me this past spring, and I repaired it the
same way.  I got a good used replacement from Craig Cowan at the CT VW show
and posted all this on the list.

Mike B.

-----Original Message-----
From: Stephen Grisanti
Sent: Tuesday, February 15, 2011 5:41 PM
To: vanagon@GERRY.VANAGON.COM
Subject: Re: Broken Fuel Pump - Was: Fuel pump

I had the filter loose and was trying to get the hose linking pump-to-filter
loose at the pump end and in wrestling with it managed to snap off the
plastic nipple on that (the rearmost) end of the fuel pump.  The outlet end.
I posted about it years ago.  Just one of those intensely maddening things.
I had no idea the damn thing was plastic.  I've been a lot more careful ever
since.  That's one reason I like getting parts from vans in junkyards; you
get practice removing things before having to do it on your own van and may
therefore have a better idea of how to approach that task when the time
comes.

I was able to splint the outlet end together again using extremely thinwall
tubing from a hobby shop to make an inner sleeve, then JB Welded everything
together with some thin nylon as wrap and cast material also impregnated
with the JBW.  That pump now lives in the spares bin in the van in case I or
some hapless Vanagon owner needs one in a pinch.

Stephen

--- On Tue, 2/15/11, Jeff Lincoln <magikvw@gmail.com> wrote:

From: Jeff Lincoln <magikvw@gmail.com>
Subject: Broken Fuel Pump - Was: Fuel pump
To: "Stephen Grisanti" <bike2vcu@yahoo.com>
Cc: vanagon@gerry.vanagon.com
Date: Tuesday, February 15, 2011, 4:54 PM

On Tue, Feb 15, 2011 at 4:26 PM, Stephen Grisanti <bike2vcu@yahoo.com>
wrote:

Then there are those of us who set out to change the filter as a normal
maintenance and wind up BREAKING the fuel pump and have to replace it also.
Just one of those learning experiences where a $20/30 minute job becomes a
$200 weeklong-wait-for-the-parts-to-arrive job.  Makes you cautious about
touching anything unless you absolutely must.

Stephen

Stephen,

I mean no disrespect or any ill will but how on earth does one break the
fuel pump when changing a filter? That must have been one heck of a terrible
drag of a situation.

--
Thanks,

Jeff
'85 GL (Gertie)
'90 Carat (Grover - the noble parts donor)
'78 Bus (Melissa) Patty's Bus