2nd Gen Non-Engine/Transmission Help requested: Blower motor problems and hot wires

[David Wheeler]

It all started when the blower motor stopped working regardless of fan speed setting. The motor had been replaced approximately 2 years prior. After a little research I determined the problem was with the resistor. Ordered a new resistor and installed. Problem solved....or at least I thought. All ran fine for a couple of weeks and then the blower motor would not operate again. Then, several days later it started working again. I traced the power wires from the fan back only to find the wires on the truck power side of the fan power connector were so hot I could barely hold on to the two wires! Surprised it hasn't melted the insulation. On the other side of the wiring harness the wires are only slightly warm. Not sure where to go from here. Any suggestions would be very welcome! Thanks!

 

[B.G. Smith]

Could be just bad contact in the connector. On my 06 when it was one year old the contacts in the plug that connects to the resistor corroded and everything quit, bought a new resistor and it worked a few days and quit again, I cleaned the contact areas in the connector and it has been fine since. bg

 

[GAmes]

When the resistor fails it defaults to the fan high speed. If your new blower motor was after market it may have failed and is high in resistance, but not high enough to pop the fuse. I get mine from u-pull-it yards. About $10 and you can get the resistor for another $2 or 3. OEM is the best in this case.

 

[B.G. Smith]

When the resistor fails it defaults to the fan high speed. If your new blower motor was after market it may have failed and is high in resistance, but not high enough to pop the fuse. I get mine from u-pull-it yards. About $10 and you can get the resistor for another $2 or 3. OEM is the best in this case.

Yes, the high speed for the blower motor is direct and bypasses the resistors in the block. In other words, if the resistor goes you should still have high fan speed. bg

 

[K5IP]

The hot connector almost certainly indicated high resistance due to bad contacts in the connector. You might be able to fix it with come connector cleaner, but you might have to replace the connector (or just replace it with wire nuts)
This is probably the root of your trouble.

 

[David Wheeler]

Thank you all for your replies. I will check into cleaning the contacts in the plugs. The blower motor was likely an after-market installed by my mechanic.

 

[BarryG]

I know years ago when my oem blower went out I went to the local dealer for it, they wanted over$300 for the thing. Couldn't quite stomach that so went to AutoZone and picked on up for $50. It has lasted longer than the oem, nor did it ever blow a resistor. The oem one went through three of them however it is to some degree louder. Last winter it started squealing once in a while when it was really cold out at startup, just a chirp but it is certainly on its way.