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I dunno Bruce... I've taken the Ox-Gard out of the garage and settled on using ordinary connector grease to exclude moisture in the 12-volt electrical arena.
Used it 15 years ago, jumping on the "makes sense" posts here on this forum, but have since come away from thinking the greenish-brown goo was any better than the clear stuff smeared on terminals and fuses, learning how its formulation addresses aluminum-copper joints in higher-voltage (house wiring) applications. Also, fixing windshield leaks has all but eliminated my use of connector grease inside the cars. But that's just my preference. It certainly can't hurt.
Fixing the k-jet fuel pump wiring is indeed tricky. There are only 2 terminals in the relay socket needing replacement, and I think 3 at the fuse panel. Crimping those properly is a challenge without expensive tools. I've cheated by raiding a well-stuffed junkbox with harness scraps, using clean, undamaged factory crimps, i.e. pick'n'pull wiring.
As for the plastic housing, in practice, I have simply cut out the melted part and not bothered to renew the housing. A couple zip ties or some electrical tape keep the wires together. But, I know I have one or two housings in that junkbox in case I want a pretty repair. Also, I see the housings are still available new, and Dave Barton has made it really easy to pick these and the correct terminals on his harness parts page http://www.davebarton.com/blackvinyl.html without getting stung on minimum order and shipping costs.
Adding my thoughts to your thread was really just meant to raise your awareness about the likelihood the trouble will return at some point so you could look toward the real culprit and not decide to blame the expensive parts like pumps and relays. Heat is the result of current multiplied by resistance squared, and the heat occurs right where the resistance is, and resistance in an electrical contact rises exponentially with heat. So next time you suspect the pump isn't pumping, wet your finger before feeling those fuse and relay terminals.
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Art Benstein near Baltimore
Haunted French pancakes give me the crêpes.
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