Sorry for the hassle mule. Yeah, definitely sounds like a manuf. issue. Only problem with those is that they usually take a long time to get resolved.
Another possibility (though remote) is that over the years Ford used a couple of designs, and the suppliers are mixing them up.
I've only seen the one design though, so that's just a long shot.
So your new connector's clips were not aligned/oriented correctly? Or were they just not quite long enough to latch on to the pump? Did you have to remove material from the pump, or the connector?
Did the contacts/pins slide on ok, or were they not mating up correctly either?
Did your harness not have an original connector, or was your original different from the new pump?
Yours may have been the conversation I overheard then. And I may have misunderstood (or missed that part of the conversation), but I only heard him suggesting to open up the contact points. Nothing about the clips themselves.
I'm guessing I just missed that bit of my half of the conversation, but it's worth double-checking on Tuesday when I get in.
He also offered to take it back as well, if you'd preferred to do that at the time. Since it's on now, with luck it'll work out. But you're right, you should not have had to go to so much trouble to make it fit.
Did the later model tank even line up with the original holes in your fender?
I still wonder too, if there were any variations in pumps and connectors that Ford had over the years, or if the manufacturer is making them wrong. Guess I'll have to do some more digging.
Just what we love to do... Ugh.
Let you know what I find out.
Paul