I have read every post I could find on the subject but I still have a couple of questions.

I removed all of my AC and put in a Non AC heater box. I cut back the heater/blower motor wires and tucked them away. I'll deal with that circuit another day.

My cooling fan has not been working so I'm starting from scratch and wiring a new circuit similar to the original. (single fan)

I ordered a new cooling fan relay but the relay plug looks sort of greassy/ maybee coroded where the wires enter from the bottom.

1. Can I replace the plug that goes into the bottom of the relay? 2. Do I need any special tools to attach new wires to a fresh plug?
3. Would it be wise to use any solder when connecting fresh wires to the relay plug?
4. Can I replace the two wire plug that plugs into the coolant fan motor with a new one so that I can use new wires in that part of the circuit as well.
5. how would I remove/install fresh wires to a new cooling motor plug? Is there a special tool or something?
6. What gauge # wires should I use to the blower motor (Heavier)?
7. What gauge # wires should I use to connect the relay to the temp switch (Lighter)?
8. If I decide to add a manual fan switch can I add the second (optional) ground directly at the relay plug (right where the temp switch wire attaches)?

I know that's a lot to ask but any help will be much appreciated. Mostly I'm looking for advice on re-using / replacing the factory connectors in combination with new wires. Thanks!

 

ttt

 

you can get new plugs for relays at most big auto parts stores they will usually have a couple inches of wire attached. then you can either soldier or butt splice them then shrink tube them. or if the plug bodies are still good with a small screwdriver there is a tab to push in from the front of the plug and the terminal will pop out. then go to radio shack ect. and get new terminals and crimp your own wires on and put back in plugs. bigger wire is alawys better than smaller. 16 guage is good to 15 amps. 14 guage is good to 20 amps. and 12 guage is good 25 amps. hope this helps.