ok folks, after 2 days of talking to my good friend google im coming up blank! i have completed and test driven to great success my swapped 88 with a 02 sierra 5.3L and it is amazing over the stock 305 tbi.....but after about 15 warm ups and test and tunes and 20 miles or so of driving the plug on top of the fuel tank (stock yellow 3 prong connector) wired to an ebay special walhbro knockoff pump ( still working) the yellow connector has melted. and when i was inspecting when it was on the side of the road, was very hot! so far the only issue i have come across. anybody else have a similar issue? idk if i should run completely new wires and a new connector that is outside of the tank or what? but this is no bueno. im not prepared to do a 4th gen tank swap or any other craziness, everything is working fine except that connector on top of the sending unit is getting really hot and melting. i know the new pump draws more current, how can i cure it? thanks in advance.

 

Meow

 

It shouldnt draw that much current, so something is wrong. Are the terminals corroded? Something is causing excess resistance

Maybe tap into the ground wire and run an extra leg direct to the chassis near the tank. Can never have too many grounds

 

Thanks. I ran new wires from the new pump to an external connection just outside the tank instead of ontop of the sending unit.

 

you bought a cheap generic knockoff fuel pump.. that's your problem right there.

as far as how to fix it: get a real Walbro pump... or a company called Racetronix sells some thing called a "hotwire kit" for G bodies and other cars that uses the stock pump power wire to trigger a relay that feeds power from a wire that you run to the back of the alternator. the might sell the same thing for F bodies, or maybe the G body one would work..