TMAllison - Words of wisdom for sure. Actually, I just replaced the GPs, following Lightman's DIY. Used a few liberal doses of PB Blaster for a day or two before removing and turned gently. No serious problems, and I greased the new ones with anti-seize.

whunter - So you're saying rule out a bad #5 (even though new) and a bad harness before looking at the relay? I assume the bench test should be for both resistance and quick heating with current applied. Fair enough. But let's assume plug and harness are okay--is there any way to test the relay? Also, I thought R=1.0 ohms or less means okay for the plug.

pjc