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Dear rsbrink,
Hope you're well. I second your suggestion, that the entire send unit be replaced: if there's a leak, there's fire danger.
As you've tried almost everything, I hesitate to offer a suggestion. Instead of pulling on the "quick" disconnect fitting, once you've pulled back on the collar, push the "quick" disconnect fitting forward, as if you were pushing it onto the fitting.
If I recall correctly, I pushed to free-up a "quick" disconnect fitting on a '94 940, which has a "quick" disconnect fitting to a send unit with a single, in-tank pump (Bosch fuel management). I'm not sure why pushing on the fitting helped, but it did.
Hope this helps.
Yours faithfully,
Spook
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