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Welcome, I will do my best to help you with your issue
Yes you will need to remove the entire burner assembly if you can't reach in and pull out the thermo couple. Is sounds like you need to clean the pilot burner anyway
The pilot burner and possibly the pilot orifice should be cleaned since there is no other likely explanation for the pilot flame to miss the thermo
I see that the assembly is sort of held in place with what looks like a simple rod that the assembly slides over. Is that correct? If so I should be able simply lift the unit up after disconnection from the gas valve?
I don't remember specifically the arrangement for the FSG. The burner either slides straight out in a kind of slot in the bottom of the chamber or you lift it slightly ans slide it out. There are on bolts or any fasteners holding it in place
The pilot flame is really just to the side of the thermocouple not really directly hitting the thermocouple. Is this proper?
No it's not and likely due to a dirty pilot burner or pilot orifice
The orifice is a small thimble shaped object
To get to it you disconnect the pilot tubing from the pilot burner
it will either be on the tip of the tubing or it will stay in the burner
Actually, I have a strong pilot flame but the directional shroud seems to be not in line.
Pass a very fine wire (hole is ~0.01") through the hole. You must do this even if you can see daylight through the hole. Unless the pilot burner is real dirty an orifice obstruction could cause a misaligned pilot
I will see what I can do. Thank you.
I actually ended up physically moving the thermocouple so that it is now in the direct path of the pilot and it is working fine now. It really boiled down to not have anything to lose.