Cooling Fan Connector Issue

[Rick Norwood]

I have been dealing with an intermittent overheating problem on my 2014 Traverse LS 3.6L V6. I originally thought it was a fuse box problem, but I have discovered what I believe is/was the main culprit. Going back about 5 years ago, the main fuse box actually melted around the Fan Relays and had to be replaced. Fast forward to about a couple of weeks ago, to cut to the chase, I couldn’t get Radiator Fan #1 to come on. I disconnected the 4 Wire Connector to the Radiator Cooling Fans (to connect jumper wires directly from the Battery to make sure Fan #1 was good) and found my Problem. Apparently, when the Fuse Box Melted, so did the Cooling Fan Wire Connector. The Connector was Burnt and Melted INTERNALLY. Strangely, you couldn’t see any of this damage on the outside of the connector, the damage is only visible from the inside when the connector is pulled apart.

Male and Female sides of the connector:
https://imagizer.imageshack.com/img924/8327/hvuNih.jpg

https://imagizer.imageshack.com/img923/8655/iLmuqx.jpg

Actual connector after removal:
https://imagizer.imageshack.com/img923/3418/rWfMAr.jpg

Once I verified that both fans were good using jumper wires, I cut each of the 4 Connector wires (one set at a time) being careful to connect the correct wires from each side of the connector to its respective mate, and spliced them together with solder butt connectors (available on Amazon) and a Heat Gun.

Solder Butt Connectors: The silver ring in the middle is solder, the colored rings at each end are adhesive, and the clear tubing is actually Shrink Tubing. These connectors provide a water tight connection when done properly with a Heat Gun! Note: using an open flame like a cigarette lighter will turn the tubing Black, I don’t recommend it.

https://imagizer.imageshack.com/img923/4216/8MGQGw.jpg

As a side note, the colors of the wires on the female side of the connector are different than on the male side of the connector. (Thanks GM ) so be very careful if you have to perform this surgery to keep your wires straight. Again, cut one wire at a time on one side of the connector, then cut the wire directly across the connector on the opposite side, then splice them.

If you are having an intermittent fan or cooling issue, pull the Cooling Fan Wiring Connector apart and inspect it. If it doesn’t look burnt or melted, I suggest you spray it liberally with Electrical Contact Cleaner and re-assemble the connector. If you do find that it is Burnt and/or melted, you may be able to buy a replacement connector, but it may be pricey. I suggest removing the connector and soldering the wires together directly.

With burnt contacts and melted connector, I seriously doubt that I was getting a solid electrical connection, resulting in the intermittent Fan problem. After my repair, my fans are working perfectly.