Let’s first try to understand what Fender is doing in their reverb circuit.
There is a large loss of high end signal going through the mechanical reverb springs so the high end needs to be greatly boosted on the driver side. This is done in the output driver stage which is a high pass filter with a lot of gain.
But Fender goes even further, again amplifying the high end in the reverb return circuit with another high pass gain due to R40 and C26. C28 then cuts some low end. All this to make up for the loss of high end in the reverb springs.
But in an FX loop we don’t want any of that. We just want unity gain and a flat frequency response.
The reverb send has an interesting twist, in that the “ground” pin (P14) isn’t tied directly to ground but to the negative input of the opamp. I suspect this is a trick to reduce (cancel) hum picked up by the cable to the reverb element. But you shouldn’t need that if you’re just driving a standard guitar cable to an fx box.
The output driver U5 is just a basic opamp that happens to be able to drive higher currents than a standard opamp but certainly doesn’t have to. It can be used directly to drive the fx send but it’s a good idea to put a small resistor on the output to provide some short circuit protection.
There’s also a light low pass filter (7kHz) in the previous stage. That has fairly negligible effect but you can reduce C22 to 47pF or eliminate it entirely if it bothers you.
The small C25 on the receiver is just for RF immunity and should be left in place – it won’t affect audio at all.
C28 (.015uF) is providing an unwanted cut in low end, but it also is providing a desired block of any unwanted DC offset imparted by the fx loop. So we want to increase it, not eliminate it.
I would suggest the following:
- Remove R45 (or C29). This eliminates the high pass amplification on the send.
- Add a 1K resistor to P13, take send’s hot output (tip) from other side of 1K.
- Attach send’s shield to ground, not to P14.
- Remove R40 (or C26). This eliminates the high pass amplification on the receiver.
- Increase C28 to 0.1uF. This provides full audio bandwidth on the receiver.
Edit (after your comment that the signal levels are still too small):
There’s not really enough information in the schematic snippet to really know what the absolute levels are through the system so we’re left with some trial and error.
Before adjusting the gain on the return path we need to make sure the level we’re sending to your fx box is correct. You can check that by listening to your fx box output directly and/or looking at its input meter if it has one. If it’s too soft then we need to boost the send level.
There are two ways to do that. One is to increase R35 in the previous stage, but it's already pretty big so I'd opt to put the gain in the final stage. Do that by putting back R45, but connecting it straight to ground rather than through C29. The gain is 1 + (R44/R45). With R45 not present (infinity) the gain is one. R45 = 22K then gain = 2 = +6dB. Find the gain that makes your fx box happy.
Note: if R45 ends up being bigger than about 500 Ohms (likely) then you can actually put C29 back in: the rolloff won't be in the audio band and you'll leave your Frontman a little closer to original condition.
Your fx box should have a nominal gain of one, so now you can adjust the gain if necessary on the return path. Again, there are two places to do that. Decreasing R43 will work but only to a point: if it gets too small it will affect the linearity of R42 and you might have to make C28 even bigger. Ideally it stays bigger than the 50K pot.
The better place to add gain is in the opamp. If you restore R40, connecting it straight to ground instead of through C26, the gain of that stage is 1 + R41/R40. Making both 3.3K will give you +6dB and is a good starting point.