ICQ(10349587) me or post:

I need help with my fan relay. I identified all the wired inside and what the do, but the constant power lead (labelled "Fusible Link") gets so hot it melted its place in the weatherpak and scorched the printed circuit in the relay. I have a hi-level lighting relay (30A), will this work, or will the power line melt this one too? I need a fan and not an electrical fire. How do I fix?

(note, the wire to the fan is bigger than the power-in, does this matter?)

 

Yes is does.

All of your problem may be happening due to that as well.

 

I assume that you are referring to the plug that goes into the relay. If that is the case the reason the wire is getting hot is because you have a high resistance connection. The spade end in the plug is probably burnt, this is a fairly common occurence in auto electrical systems. The ONLY way to fix it right is to get a new relay, and replace the contact in the plug or the alternate get a new fan relay connector complete. Places like auto zone and pep boys do stock complete assembled connectors. I would use non insulated butt connectors and several layers of heat shrinkable tubing. Throw some black conduit over your work and it will look OE. Also with the butt splices after you crimp them I like to flow the joint with 60-40 electronic solder. If you try to fix it by just cleaning it you will be doing it again and again etc. Once the plating burns at the joint it will never be electrically secure for any period of time. Ever see a batt terminal begin to smoke when trying to start a car, same thing here. There is resistance in the connection and it begins to generate HEAT, sometimes lot's of it. I have seen them get so hot that you can't get the plug disconnected from the relay. The difference in wire size has nothing to do with your problem. The fuse will determine the amount of allowable current to flow in the circuit, and both wires are plenty large enough. You can buy kit's to repair these connectors, but they can be a pain if you are not familiar with working with them.

 

Going out ot replace the whole thing!