1996 4dr 4x4. About 3 weeks ago, I lost the high speed fan - relay checked bad, so swapped that out and everything was great. Today "100 degree's" was on I40 and wife said she was too cold, switched fan from high to medium and "bam" lost all fan settings.

I've checked over everything and when I got to the relay, I found the relay burned where the "constant hot" plugs into it. The connector and the realy are melted right there.

Now I know that the relay is 99% toast - but now I am wondering what has caused that?

Could a bad resistor contribute to this? Whatever it is, it obviously contributed to the first realy going bad - but totally fried this one.

any help appreciated.

Rick

 

How did the connection look whn you replaced the relay the first time. Corrosion at a spade terminal can cause high resistance and heat which will further weaken the connection. I would first try replacing the relay block (what the relay mounts into) and see how it goes from there.

I doubt that the resistor is at fault. The relay only controls high speed which has nothing to do with the resistor.

 

To be honest, I don't know. But you make a good point - I will replace the block and install new relay too.

I already ordered a new resistor, so will put that in as well - keep the old for a spare. It was only like $13.