Catching up on this.... yes, I've disassembled the fuse block and there is no evidence of any over heating, no melted posts, nothing I can find.
So getting up to date, I've removed the intake manifold for a 2nd time and looked at the fan switch pigtail and checked it for continuity, all good. I've opened up the wiring split casing as much as I can and looked for burnt wires, found nothing. I've purchased a new relay and swapped it out for the low speed, high speed and PCM relays and rotated the relays w/ in the fuse box. No change.
I've looked at all the wires coming from the fuse box to the fan connector and there are no burnt wires. While the fan was out we tested and looked for any evidence of bad wires or melting. Nothing. Fan tests good on both high and low speeds.
I did some tests where the pigtail connector for the fan switch connects to the wiring harness. I used a multimeter and I'm getting ~4.5v at the connection point. From there I shorted out the the fan switch harness connector w/ a paper clip to complete the circuit.
I put my multimeter on the ground and low speed wire connector that attaches to the fan. W/ the fan switch shorted, I receive 0 volts at the fan connector.
I'm too the point of just doing the wiring reroute. Would someone be kind enough to post up how to do this reroute please? I'd appreciate a technical write up and some pics.