melted wires on blower motor reistor - Jeep Wrangler Forum

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Old 05-12-2008, 01:42 PM   #1
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melted wires on blower motor reistor

Hey all, I took the kick guard off and had a look at my blower motor resistor and I noticed that the cover on one of the wires has melted almost totally off of the wire.. thoughts or suggestions??

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Old 05-12-2008, 02:37 PM   #2
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That's pretty common, it happened to mine too. The fan motor draws a lot of current so it has a habit of damaging the resistor pack, wiring, and often the fan speed switch too. And fan motors can start going bad too where it starts drawing more current which will accelerate damage to those components.

The last repair to my fan motor circuitry involved replacing the resistor pack and splicing new wiring in to replace the wiring that was smoked. In my case, I think I had two wires that were smoked I had to splice around in addition to a bad resistor pack that. That's been 4-5 years now and it's been ok since then, thankfully it appears my fan motor is still ok based on that.

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Old 05-12-2008, 06:00 PM   #3
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What gauge wire did you use in the splice?, assuming you didn't just splice them by twisting the wires together and leave it at that, what did you use to hold the splice? sorry for the questions
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Old 05-12-2008, 06:03 PM   #4
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I used 12 gauge wire and I soldered the splices into place, covered by two layers of heat shrink tubing and buttoned it up. I bypassed (eliminated) the connector with the spliced wires as the connector was damaged from the heat too.
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Old 05-12-2008, 06:11 PM   #5
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any suggestions for someone that doesn't have a soldered tool? Thanks for the help!
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Old 05-12-2008, 06:21 PM   #6
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any suggestions for someone that doesn't have a soldered tool? Thanks for the help!
Well, you can always use some insulated butt splices but you'll need a crimping tool for them and use care to crimp them solidly. I'd follow that up with several layers of good quality electrical tape that over lap the butt splices by at least an inch or two. Any Home Depot type hardware store carries them. They're sized according to the gauge wire you'll be butt-splicing.

A butt splice looks like this...


If the store is especially well equipped with splices, you might even find one that has solder inside that melts just from a heat gun.
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Old 05-12-2008, 07:50 PM   #7
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awesome, thanks for the advice, would a pair of pliers work as a crimping tool? I will have to give the suggestion a try! You think something like just putting new heat shrink tubing over the existing wire would work? I am just trying to go as simple as possible! Thanks again for the help bro.
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Old 05-12-2008, 08:23 PM   #8
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a soldering iron for light duty like that is about 10 bucks.. buying the right crimping pliers cost more than a soldering iron.. do it the right way IMO,
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Old 05-12-2008, 09:00 PM   #9
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I have just never soldered anything before... can you take the entire wire part out of the Jeep?, I didn't look to see if the wire harness had another wire harness on the other end of the wires..
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Old 05-12-2008, 11:12 PM   #10
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Soldering is easy and that’s for sure they way to go. Twist the wires with the exposed ends facing one another not the other way around. Just heat the iron up and hold it on the exposed part. Test it by touching your solder to the exposed wire with the iron still on it. Soon after the solder will start melting and the wire will soak it up like a sponge. I would recommend getting rosin core solder too. It's really easy and what you can do is grab an old block of wood. Lay it under your exposed wires and use as a pressure point to get the wire good and hot plus it gives you a workspace without worry of melting some plastic. You can then just wrap it up with some electrical tape. The heat shrink tubing is nice if ya want to spring the cash for it. It's pretty cheap. If you’re going to throw some loom over it it's not a huge deal.

Here is some paint art I whipped up to show ya how to twist the wire. ( Do Not Hate On My Paint Skillz!)
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Old 05-12-2008, 11:42 PM   #11
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If you are't already familiar with soldering, these aren't the wires to learn on. I'd go with the butt-splices and use the correct crimping tool that will be sold right next to them. Give them a good solid crimp, and no, pliers will not give them the kind of crimp required.

This is a fairly high amperage area, you're safer and better off crimping them together using butt splices. Ether cover the splices with electrical tape or a couple layers of heat shrink insulating tubing. On second thought, just use electrical tape. Give them several layers of good secure wraps of tape so they can't later short out from vibration or heat.
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Old 05-12-2008, 11:45 PM   #12
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You could always find some spare wire around the house. Same gauge if possible. Do some pratice runs it's not hard.
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Old 05-13-2008, 05:04 AM   #13
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JP Magazine has a repair/upgrade for this problem. They wired in extra relays for each fan speed. I'll try and find the article tonight when I get home.
Bert
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Old 05-13-2008, 11:08 AM   #14
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You could always find some spare wire around the house. Same gauge if possible. Do some pratice runs it's not hard.
It's not hard to learn how to solder, you are correct. But when learning to solder on your own without someone there to provide a little guidance, it's not that easy to solder a good joint your first couple go-arounds... let alone be able to know a good solder joint from a bad solder joint. Though soldering really is a fairly easy skill to pick up, I just wouldn't choose this particular job as the one to "go live with" after practicing on just a few wires ahead of time.

Just that in this particular situation, where he's faced with cutting off the burned portions of the existing wiring, there's no extra length of wire in reserve he can get to if the soldering doesn't go well. That's why I suggested crimped butt-splices as a safer easier repair.

THEN he can go learn how to solder and use those new soldering skills elsewhere where it's such a handy skill to use. I dunno what I'd do if I didn't know how to solder.
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Old 05-13-2008, 11:52 AM   #15
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Quote:
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JP Magazine has a repair/upgrade for this problem. They wired in extra relays for each fan speed. I'll try and find the article tonight when I get home.
Bert
The October 2007 issue of JP Magazine has a decent article titled "Retardant"...TJ Dash Fire Prevention.
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Old 05-13-2008, 01:29 PM   #16
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yeah, I think I am going to stick with the butt splicing.. appreciate all the help! I already replaced the fan switch since it was melted out (and I broke the AC switch messing with it so its been replaced) so now I just need to replace the blower motor resistor, I just didn't expect to find melted wires! If anyone lives around Auburn AL and wants to teach someone how to solder I am up for it, otherwise I think I will keep it stupid people simple! Going to have to pick up a solder iron and learn how to do that properly, I just never thought that was a skill I would need!!! Thanks again guys, this site has proven to be really helpful!!! Oh, 1 last question, should I totally unplug the battery when doing this or is unplugging the negative contact enough?
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Old 05-13-2008, 01:35 PM   #17
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oh yea, Ripcord, I thought the artwork was ACE.. thanks for the easy to follow instructions!!
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Old 05-13-2008, 01:37 PM   #18
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Just keep the ignition key out or in the Off position and nothing will be live around that fan switch, motor, or resistor pack... no need to disco the battery.
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Old 05-13-2008, 04:03 PM   #19
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No problem after installing police equip for 5 years I despise any kind of butt splice. I solder everything. You should pratice tho it doesn't take long to learn the diff between a bad solder and a good one. The wire will soak it in. Key is you have to get the wires hot enuff.

Good Luck!

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