MY ORIGINAL FAN MOTOR WENT OUT, REPLACED IT WITH AN AUTOZONE LIFETIME, & THEN A FEW MONTHS GO BY & I SMELLED SOMETHING KINDA BURNING, LOOKED UNDER THE HOOD, & THE FAN RELAY WIRES WERE REALLY HOT & HAD MELTED SOME. THE CONNECTIONS ON THE RELAY WERE CHARRED. SO I TOOK THE FAN MOTOR BACK, GOT ANOTHER ONE, HOOKED IT UP & THE SAME THING HAPPENS. SO I WIRED THE FAN DIRECTLY TO THE BATTERY, WITH A SEPERATE FUSED RELAY & GROUND WITH HEAVIER GAUGE WIRE, & AFTER THREE MONTHS OR SO THE FUSE HOLDER WILL COMPLETELY BE BURNT UP, & THE FAN WON'T WORK UNTIL I PUT A NEW FUSE HOLDER. I HAVE REPLACED THE FUSE HOLDER TWICE IN SIX MONTHS, BECAUSE IT JUST CHARRS UP. IT'S OBVIOUSLY DRAWING TO MUCH CURRENT, I THINK AUTOZONE FAN MOTORS MUST BE BAD, BUT THEY CLAIM THEY ARE NOT. THE FAN COOLS GREAT, WHAT DO U GUYS THINK. 305 TBI SINGLE FAN.

 

Did you insure the ground side of the fan circuit has good,
corrosion free connection?

 

Its likely that the motor is shot. Bad ground will cause lots of heat at the ground connection itself. Everything melting means there is an excessive load on the circuit from the motor. After my stock motor and all the wiring burst into flames, I replaced it with a Siemens unit from Poop-Boys. Its held up fairly well for the past five years or so.

 

Sounds like it draws a lot more current than the original. It could be supposed to do so, it could be a fault, a design flaw, or a manufacturing error. Just for the record, what does the box say about current draw and other technical data, and what size fuse & wire did you use?