I need a replacement plug for the heater blower relay in my 95 Chevy
pickup truck. Everytime I turned on that blower motor lately, I have
been smelling a hot sweet smell of something overheated. Shutting off
the blower stopped the smell.

The blower motor and associated wiring in these mid 90's trucks are
notorious for electrical failures and even some fires. A year ago, my
blower stopped working, and I found a plug was melted. I removed it, and
soldered the wires together. (That plug was undersized when
manufactured, and is the #1 cause of fires). I eliminated it!

Today I ripped the dashboard apart again, and traced the wires. Nothing
was burned that I could see. After having a bucket of water handy in
case of fire, I left all the wiring exposed and let that blower run.
Soon I smelled the hot odor and began sniffing around. The odor was
around that same wiring area, and near the blower motor, but the blower
itself was not hot, nor was it's feed wire.I left it run longer and the
odor got stronger. Eventually I noticed a little smoke, and then the
blower stopped. I reached down there and almost burned my hand on the
heater relay and one of the wires behind it.

I unplugged the relay, and found one of the five contacts was burned and
the plastic around it on both the relay and the plug melted. That exact
same sweet smoky odor was very strong on that relay.

The local auto parts stores have the relay. But none of them have the
plug. I suppose I could order the whole wiring harness from a Chevy
dealer for a huge price, but that's not gonna happen.

We have no auto salvage yards around here.
Where can I get a plug?

This is the exact relay: (photo included)
http://www.truckerac.com/blower-rela...712077864.html

No, I cant use those 1/4" crimp on terminals, these terminals are
roughly 1/8".

On Thu, 12 May 2016 23:30:12 -0400, wrote:

I need a replacement plug for the heater blower relay in my 95 Chevy
pickup truck. Everytime I turned on that blower motor lately, I have
been smelling a hot sweet smell of something overheated. Shutting off
the blower stopped the smell.

The blower motor and associated wiring in these mid 90's trucks are
notorious for electrical failures and even some fires. A year ago, my
blower stopped working, and I found a plug was melted. I removed it, and
soldered the wires together. (That plug was undersized when
manufactured, and is the #1 cause of fires). I eliminated it!

Today I ripped the dashboard apart again, and traced the wires. Nothing
was burned that I could see. After having a bucket of water handy in
case of fire, I left all the wiring exposed and let that blower run.
Soon I smelled the hot odor and began sniffing around. The odor was
around that same wiring area, and near the blower motor, but the blower
itself was not hot, nor was it's feed wire.I left it run longer and the
odor got stronger. Eventually I noticed a little smoke, and then the
blower stopped. I reached down there and almost burned my hand on the
heater relay and one of the wires behind it.

I unplugged the relay, and found one of the five contacts was burned and
the plastic around it on both the relay and the plug melted. That exact
same sweet smoky odor was very strong on that relay.

The local auto parts stores have the relay. But none of them have the
plug. I suppose I could order the whole wiring harness from a Chevy
dealer for a huge price, but that's not gonna happen.

We have no auto salvage yards around here.
Where can I get a plug?

This is the exact relay: (photo included)
http://www.truckerac.com/blower-rela...712077864.html

No, I cant use those 1/4" crimp on terminals, these terminals are
roughly 1/8".



http://www.repairconnector.com/categ...-AND-PIGTAILS/
Repair pigtails for just about anything.

On Fri, 13 May 2016 01:26:46 -0400, wrote:

On Thu, 12 May 2016 23:30:12 -0400, wrote:

I need a replacement plug for the heater blower relay in my 95 Chevy
pickup truck. Everytime I turned on that blower motor lately, I have
been smelling a hot sweet smell of something overheated. Shutting off
the blower stopped the smell.

The blower motor and associated wiring in these mid 90's trucks are
notorious for electrical failures and even some fires. A year ago, my
blower stopped working, and I found a plug was melted. I removed it, and
soldered the wires together. (That plug was undersized when
manufactured, and is the #1 cause of fires). I eliminated it!

Today I ripped the dashboard apart again, and traced the wires. Nothing
was burned that I could see. After having a bucket of water handy in
case of fire, I left all the wiring exposed and let that blower run.
Soon I smelled the hot odor and began sniffing around. The odor was
around that same wiring area, and near the blower motor, but the blower
itself was not hot, nor was it's feed wire.I left it run longer and the
odor got stronger. Eventually I noticed a little smoke, and then the
blower stopped. I reached down there and almost burned my hand on the
heater relay and one of the wires behind it.

I unplugged the relay, and found one of the five contacts was burned and
the plastic around it on both the relay and the plug melted. That exact
same sweet smoky odor was very strong on that relay.

The local auto parts stores have the relay. But none of them have the
plug. I suppose I could order the whole wiring harness from a Chevy
dealer for a huge price, but that's not gonna happen.

We have no auto salvage yards around here.
Where can I get a plug?

This is the exact relay: (photo included)
http://www.truckerac.com/blower-rela...712077864.html

No, I cant use those 1/4" crimp on terminals, these terminals are
roughly 1/8".



http://www.repairconnector.com/categ...-AND-PIGTAILS/
Repair pigtails for just about anything.

Wow, I never knew there was a company that made repair plugs. This is
not the first time I needed something like this, but this is more
critical than most of the others I needed, like for tail lights....

Thanks for the URL.

On Thu, 12 May 2016 23:30:12 -0400
wrote:

From:
Subject: Need replacement plug for heater blower relay
Date: Thu, 12 May 2016 23:30:12 -0400
Newsgroups: alt.home.repair
Organization: Aioe.org NNTP Server
X-Newsreader: Forte Agent 2.0/32.652

I need a replacement plug for the heater blower relay

Is there anything you can do and or find on your own?

On Fri, 13 May 2016 20:22:57 -0400, wrote:




This is the exact relay: (photo included)
http://www.truckerac.com/blower-rela...712077864.html

No, I cant use those 1/4" crimp on terminals, these terminals are
roughly 1/8".



http://www.repairconnector.com/categ...-AND-PIGTAILS/
Repair pigtails for just about anything.

Wow, I never knew there was a company that made repair plugs. This is
not the first time I needed something like this, but this is more
critical than most of the others I needed, like for tail lights....

Thanks for the URL.

There are quite a few companies that make repair plugs. Auto mechanics
like myself have been sourcing and using them for several decades to
repair colision damaged harnesses as well ad corrosion damage etc.

I might need to get some of the websites and/or phone numbers for them.
I emailed the place URL above, last night, and never got a reply. I may
be a little impatient. but I figure that a business shoud reply on the
next full business day, and that was today. They have no listed phone
number on their website, and only have one of those "fill out a form"
emails. With those, I never know if they get it or not. At least with my
own wmail software I can confirm it was sent.

No auto parts stores have it (nearby) and one from a big city which is 2
hours away, could not comprehend what I wanted, and after I told the
droid that it was mounted on top of the heater box (SIX TIMES), he
insisted I was wrong and it's part of my fuse box. (I hung up).

I have now spent close to 15 hours trying to locate this damn plug and
still am nowhere. (Except the Chevy dealer told me they could *MAYBE*
have one custom made for $60 to $110 dollars). NO THANKS!

On Fri, 13 May 2016 04:13:47 -0400, wrote:

On Fri, 13 May 2016 01:26:46 -0400, wrote:

On Thu, 12 May 2016 23:30:12 -0400, wrote:

I need a replacement plug for the heater blower relay in my 95 Chevy
pickup truck. Everytime I turned on that blower motor lately, I have
been smelling a hot sweet smell of something overheated. Shutting off
the blower stopped the smell.

The blower motor and associated wiring in these mid 90's trucks are
notorious for electrical failures and even some fires. A year ago, my
blower stopped working, and I found a plug was melted. I removed it, and
soldered the wires together. (That plug was undersized when
manufactured, and is the #1 cause of fires). I eliminated it!

Today I ripped the dashboard apart again, and traced the wires. Nothing
was burned that I could see. After having a bucket of water handy in
case of fire, I left all the wiring exposed and let that blower run.
Soon I smelled the hot odor and began sniffing around. The odor was
around that same wiring area, and near the blower motor, but the blower
itself was not hot, nor was it's feed wire.I left it run longer and the
odor got stronger. Eventually I noticed a little smoke, and then the
blower stopped. I reached down there and almost burned my hand on the
heater relay and one of the wires behind it.

I unplugged the relay, and found one of the five contacts was burned and
the plastic around it on both the relay and the plug melted. That exact
same sweet smoky odor was very strong on that relay.

The local auto parts stores have the relay. But none of them have the
plug. I suppose I could order the whole wiring harness from a Chevy
dealer for a huge price, but that's not gonna happen.

We have no auto salvage yards around here.
Where can I get a plug?

This is the exact relay: (photo included)
http://www.truckerac.com/blower-rela...712077864.html

No, I cant use those 1/4" crimp on terminals, these terminals are
roughly 1/8".



http://www.repairconnector.com/categ...-AND-PIGTAILS/
Repair pigtails for just about anything.

Wow, I never knew there was a company that made repair plugs. This is
not the first time I needed something like this, but this is more
critical than most of the others I needed, like for tail lights....

Thanks for the URL.

There are quite a few companies that make repair plugs. Auto mechanics
like myself have been sourcing and using them for several decades to
repair colision damaged harnesses as well ad corrosion damage etc.

If it was my vehicle, I would use a heavy-duty on-off switch with wires soldered at the switch and at the place where the relay was formerly located. Put the switch as close as possible to the heater but where you can still reach it to turn the heater on and off. Use good heavy wire and test it for several minutes before putting the switch in its final location.

On Fri, 13 May 2016 21:43:58 -0700 (PDT), wrote:

If it was my vehicle, I would use a heavy-duty on-off switch with wires soldered at the switch and at the place where the relay was formerly located. Put the switch as close as possible to the heater but where you can still reach it to turn the heater on and off. Use good heavy wire and test it for several minutes before putting the switch in its final location.
A 30 or 50 amp switch..

I'd be a whole lot more likely to use a generic relay with a readilly
available (industrial?) socket.if I could not source the correct
socket. Preserve the function when possible - and it is almost always
possible.

posted for all of us...



On Fri, 13 May 2016 21:43:58 -0700 (PDT), wrote:

If it was my vehicle, I would use a heavy-duty on-off switch with wires soldered at the switch and at the place where the relay was formerly located. Put the switch as close as possible to the heater but where you can still reach it to turn the heater on and off. Use good heavy wire and test it for several minutes before putting the switch in its final location.
A 30 or 50 amp switch..

I'd be a whole lot more likely to use a generic relay with a readilly
available (industrial?) socket.if I could not source the correct
socket. Preserve the function when possible - and it is almost always
possible.

+1 He has a lot of stuff burning up... I would check the draw on these
because that hot isn't normal.

--
Tekkie