Yeah I cant figure out how to remove these terminals. This is driving me nuts.

 

If the socket is a bit loose or corroded, that would increase the electrical resistance, which increases the amount of power dissipated in it (AKA heat). It would not even need to arc. (Not that 6A would arc much anyway.) Just poor contact is enough to cause a connector to heat up.

Does your fusebox have a cover? Sometimes people loose it, and then everything inside starts to corrode. Or maybe it got wet. Might be worth taking it apart to assess its condition.

 

As far as I know, you can't remove those terminals. They are part of the circuit board.

 

They look like they can be removed. They are just wires with a female connector on the end, pushed into the box and "locked" into place. I can still wiggle them forward and back but cant withdraw them out. There is no circuit board. And the empty spots all have these "tabs" on them that push away like I labeled in the photo. Seems no one on the internet knows how to remove these.

 

Alright no one on the internet knows how to remove these terminals, but now I do LOL

That "plastic bar" that I wrote about in the green text in the picture. If you go on the "BACKSIDE" of the relay box which is the side that is closest to the steering wheel. You can pull that "plastic bar" outwards. Its like a tray of bars that slide under the relay box. So the terminals are being held in place 1st by the tab they click into, then 2nd you slide the bar back under them. So that's how they come in and out.

Fixed up my burnt wire, and re bent the terminal ends for a clean connection.

Switched out my Oil Pressure Sensor

Plugged everything back together and my 375k all original c1500 is driving like she always has, a champ.

I noticed the new relay still gets "warm" but its not like how it was before. Before it was scorching hot instantly. So I got a few extra relays, I'm going to drive her until she breaks, and then if its the relay melting. I have a new complete relay connector/and relay unit, that I'll going to cut the fuel relay wires and just wire in a whole new connector and unit and go from there. But yeah. Trucks running good. Hopefully this is it for my "fuel gremlin" that has popped up back and forth these past few years.

 

nice work, and thank you for following up.