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When the wiring was new it could handle the loads. Years of dirt, grime, corrosion and wear on the system, the system is just not up to the challenge. Of course every truck is different. Maintenance goes a long way. YMMV

No other relay on the truck that is the same. GM - 25523703 NAPA - HR143 - $9 Orielly's - R636 - $8 Do we need to start a horn issue thread as this one started as a melted headlight fuse?

There is no real switch. Just a tab inside the horn button that makes a ground conection. You should be able to just remove the button. Some disassembly may be required.

Yes to the grill removal. Remove the headlight trim and then the grill.

Here are some pictures of the horn diode. You have to peel the duct tape back and cut the diode out if neccessary.

Good catch DH. When I wrote the Headlight Circuit sticky, I had posted the connection about the headlight and horn fuses, but I didn't take it a step further. Yes, the headlight fuse supplies many different circuits. One of the circuits is the Courtesy lamp fuse. There is a metal jumper from...

Read the headlight sticky. While it doesn't solve your problem it does explain why.