I'm still having a terrible time trying to find a short that continues to blow fuse #5 and am not sure what to do from here. My efforts don't seem to be doing anything other than making the Buss Fuse Company richer.

Background - About a month ago the #5 (courtesy light, door lights, cargo light, clock, glove box, vanity mirror light) fuse blew. There was a burning smell too. I pulled the fuse panel and found I had a meltdown on fuse #1 (fuel pump). Don't know if the meltdown caused the #5 to blow.

I never found an obvious reason for the meltdown, but the FAQ said sometimes cracked solder in the fuel pump relay can cause enough resistance to melt a fusebox. Replaced the fuel pump relay, replaced the fusebox w/ new, and soldered every crimp connection at the fusebox. Been driving for about 2 weeks now and find that the base of the new fuel pump relay does get a little warm but not much. The FAQ also said that is normal. The power window relay gets hot...related? I just re-read aleekat's post about the in-tank pump. Somehow missed that before. I wonder if that was the problem with the fuel pump fuse? I changed the in-tank pump a few years ago just because of age.

My big problem continues to be related to the #5 circuit. I haven't found a reason why the #5 keeps blowing. I've removed the interior lights altogether because the FAQ said those are prone to failure. I have removed the wires at the fusebox and the engine / cargo light wire and the door / courtesy light wire. Both of those are grounding out to the chassis somewhere as indicated with an ohmmeter connected between those two wires and chassis.

Other symptoms; turning on the radio sets off the door chime (no additional fuses are blown and the interior lights wires are still disconnected), the door chime rings for just a second when starting to put the key in the ignition (same wires are disconnected and the radio fuse # 14 is pulled at this point). Insert the key all the way and the chime stops.

The FAQ has been very helpful, but I’m afraid these symptoms are beyond it’s expertise at this point.

Please, help, suggestions? Sorry for the long post.