Tank Assembly problems of the 1996 Chevrolet K1500

This letter is to provide information regarding a hazardous and potentially catastrophic materiel defect on the 1996 Chevrolet pickup (model: K1500 1/2 ton 4. 3 l f/I v6). The vehicle had 112231 original mi. And was operated consistent with its intended use. The vehicle is production representative with no modifications or history of damage. On 20 Apr 04 while driving approximately 25 mi/hr the engine quit running with no impending indications of a failure. Subsequent inspection and repair was conducted by a certified mechanic at ron's firestone, geneva, al. Inspection revealed that the connector at the top of the fuel level sending unit shorted-out and melted and that approximately 2. 5 in. Of the plastic insulation on the gray wire from the fuel pump to the sending unit was melted. Ron blair (owner/mechanic) commented: wiring inside gas tank was melted all the way down to the fuel pump. If fuel tank had not been full it is possible for the tank to have blown up. I have never seen one do this before.