95 Chevy 1500 (Fan Connector)

[userpete1037]

Okay,
I own a 95 Chevy 1500 350/5.7, anyway the connector behind the glove box that controls the fan burned out. I'm sorry, it has 2 wires on each side red/black and they connect togther. I went to a scrap yard and bought another one and spliced into the wires and replaced it. I've noticed when I cut my fan on HI, the black wire on one side of the connector gets extremely hot. If I cut it down a notch, it cools down. What is making that wire get so hot when it's on HI because obviously that's why my previous connector burn out. Could it be the resistor pack because i replaced it a couple of years ago because my controls would work on LO or HI but found out later that wasn't the problem. The problem then was I had a bad switch. But back to my prevoius question, what could be causing that wire to so hot?

[userpete1037]

Okay, I've tried a couple of things but still didn't fix the problem. First off, i checked my hi blower relay and it had to leads that looked bad. I replaced it thinking that would fix it but no. Second thing is i put a new connector on my ground wire because it looked really bad. Thought that would fix it but that didn't do it either. I even replaced the resistor pack because i thought my old one was faulty but that didn't work either. So now i'm stuck and confused. The only other thing i can think of is there may be some thing wrong with my a/c heater controller. I'm just not understanding why those wire get extremely hot when i cut my fan on HI.

[MT-2500]

Are the plug in connections good and tight?
A lose connection will build heat.
Does it heat some on low speeds to?

How many amps is the fan pulling on high?

[userpete1037]

My next step is to check the connections at the controller and the back of the fuse box to see if everything is in order. But as far as the connections at the blower motor, resistor pack and blower relay, everything looked tight and snug.

[MT-2500]

How many amps is the fan pulling on high speed and low speed?

[userpete1037]

Where is the best place to take that reading? Do i need to take it at the blower motor?

[MT-2500]

Yes or anyplace on the positive side of battery system.
You will need a good amp meter ot volt/ohm meter that will read the system amps.

[userpete1037]

I may be able to get to it after work. Are their any readings I should be looking for? What range?

[MT-2500]

How many amps is it pulling.
Does the wires heat up on all speeds?
Are they just warm to the touch or will they burn your fingers.
Check all wire terminals for being tight.
Check the manfacture for specs.
I always like to keep the amp draw under 75% of the fuse rating.

[userpete1037]

It gets very hot to the touch when it's on HI. As far as the other speeds, warm to the touch. I will try to check it when i get home from work. If that connector wouldn't have burned out, I wouldn't have known that was my problem when my old blower motor use to go on and off. To be honest, This never occured when I had my old climate controller. Forgot to mention that I had replaced it. Maybe it started when I replaced it and just took quite some time before the connector became damaged.

[userpete1037]

I took 4 voltage readings and it dropped as the speed increased. 1st reading: 13.45V, 2nd reading: 13.30V, 3rd reading: 13.15 V, 4th reading: 13.00V.

[MT-2500]

Amps draw is the reading you need to check.
How many amps is it pulling?