On my 89 TPI there is a single wire plug near the battery that is also the power source for both cooling fans. One side of the plug is actually the fusible link. This plug like gets hot and will melt and then I don't have any power going to my fans. I've fixed the problem a couple times now...anybody else have a problem here? Maybe I am not fixing it correctly. The way I fixed it was by crimping on new terminals to the ends of the wires and replacing the plastic part. So in the end it's just like factory still with no other splices...of course the wires are slightly shorter from what I cut off. Don't know why this particular plug keeps getting hot though? I'm a bit at a lose and really don't know where to go from here...any ideas?

 

If you replace it with new fusible link and it still melts, one or both of the fan motors are probably bad and drawing too much power. I have seen the link get corroded on the inside and then blow. Cutting it shorter will not solve the problem if it is corroded, it needs to be replaced.

 

The fusible link itself never went bad and it's never been replaced. It's just the plug that's getting hot and the plastic is melting.

I wondered if a fan motor was drawing too much current but doesn't make sense why this one plug would get hot and not others or melt the fusible link.

 

I would hook up an ammeter and see the draw with the fans running. The weatherpack connector should not be melting.