Just got my son's 97 d1 back on the road after differential surgery. His fuel gauge was out so I figured Id put in a new fuel pump. Seemed pretty simple on rave. Always expecting rust and more broken parts than I need, but can't use a torch on these. Turns out the fuel line connections were so rusty even with two days of soaking in PB blaster, they wont budge without twisting the tubes coming from the pump. The questions is can I replace the rusted connectors or do I have to install all new lines? I attached a picture.

 

Someone who knows more than me will confirm or deny this, but yes you can.
Follow the rubber back to where it turns to metal, using a pipe cutter cut the metal line and then using fuel injector hose and clamps replace the rubber, you will need to use the injector clamps on the fuel pump end too.
It is not that hard to run new fuel line, just time consuming to do the whole truck, you buy a roll of tubing, feed it though and bend to fit.

 

I agree with Spike on the whole " time consuming" part. I plumbed all the brake lines on my 94. The easy part was buying the tools and tubing. It took the better part of the day to route the lines correctly and make sure there weren't any leaks. Depending on the condition of the lines I would replace them all and be done with it. I can't imagine there being much of a difference between brake and fuel lines other than the volatile nature of the fluid.

 

Cut the line immediately behind the rusted fittings. Buy these and install.
http://www.summitracing.com/parts/rnb-800-036

 

i would use compression fittings before just clamping high pressure fuel line to a straight metal piece.

if you were only fixing the return line clamps would be ok, but i wouldnt clamp the feed side.

 

Sorry for the late response. The compression fittings worked like a charm. Thanks

 

Glad to hear they worked. Its nice to give advice, but its always better to hear a success story based upon that advice and keep another Rover on the road.