Melting Fuse Box For Auxillary Fan Causes Overheat

I have a 84 533i which I am the original owner. For the last 7 years, I have been battling first a melting fuse box for the auxillary fan when it goes to the high speed. When the fuse blows, the auxillary fan stops and the car starts to overheat. I have checked and cleaned the earth ground for the auxillary fan, but when it kicks on the high speed it blows the fuse. Is my thinking correct since the auxillary fan is 20 years old, it's time to replace the fan?? I'm thinking when it kicks on the high speed there is too much resistance causing the fuse to blow. Can someone verify my thinking or respond if you've had this problem before I spend $350.00 for a new auxillary fan??

I have a 84 533i which I am the original owner. For the last 7 years, I have been battling first a melting fuse box for the auxillary fan when it goes to the high speed. When the fuse blows, the auxillary fan stops and the car starts to overheat. I have checked and cleaned the earth ground for the auxillary fan, but when it kicks on the high speed it blows the fuse. Is my thinking correct since the auxillary fan is 20 years old, it's time to replace the fan?? I'm thinking when it kicks on the high speed there is too much resistance causing the fuse to blow. Can someone verify my thinking or respond if you've had this problem before I spend $350.00 for a new auxillary fan??


Before you look at the fan purchase, check the wires that run to the two thermo switches on the top left side of your radiator. I had a similiar problem and found where the wire casing deteriorated and had an exposed wire. Also, if necessary, before you replace the fan, contact me back, I have one I can send you. I found two 533i (both an 1983 and 1984) that i stripped naked. I have a 1984 myself. Good luck, hope this will help. Tom

Tom, I found an exposed wire (black wire) on the high speed auxillary fan right where it connects to the thermo switch. What did you use to protect other than electrical tape that will quickly start falling apart because of the engine heat?? Did you use electrical shrink tape or should I replace the connector completely?? Please advise.

Hey what i did was trace the wire back as far as i could, cut and ran new wire, new connector then sleeved the entire connector with a section of rubber vacuum hose, easy fix. If you have a moment, IM me at tomferretti on aol, or tom_ferretti on yahoo.