A/C fan stopped working

Replaced the resistor last year with the updated part from Toyota, worked fine until about 3-4 months ago when it started to shut off randomly but would work on lower speeds and stay there.

Now that the weather got hot it stopped. although it did work intermittently during my testing until it completely stopped now.

Checked the power at the blower connector, nothing, although I found the connector a bit melted at the wires(not the connector)

Checked the resistor and there is no power to the resistor

I would like to note that after checking reddit I checked the fuses, using this website, and everything seemed fine, pulled the a/c controls at the console and the connector and wires look fine.


so I’m wondering what’s next for me to check and what’s likely the problem(s) needed to be fix. Would really appreciate some help and advice, thank you.

 

@Jimmyh

@Dm93

 

That splice looks suspect, I'd unwrap that and see what's going on there.

 

Oh forgot to mentioned the connector and fan has definitely being replaced before. Also I have found a few tap splice connectors on the fuse box by the steering wheel, I guess they are for the gps tracker from the dealer, don't know if that could cause a short or be a weak point for the a/c fan but wanted to mention that, I am thinking of taking off that.

 

I'd certainly investigate that melted butt splice first, poor connections generate heat which is what it looks like happened there.

 

YES when I was testing I touched the wire and it was hot. my question is should that stop the power from getting to the resistor and subsequently the blower motor fan?

 

The resistor is on the Ground side, Power to the blower motor comes direct from the HEATER Fuse (50A) when the HTR Relay is turned on.

https://www.tacomaworld.com/threads/2nd-gen-information-diagnostics.784008/#post-28042158

 

I would like to offer that I fully agree with Dm93's excellent analysis.

Loose crimp creates a heater. You probably have a melted wire and an open circuit at that crimp.

 

Alright, finally got the time to test the wire splice and bingo, that was it, cut the wire before the splice and got power, even hooked it up to the blower and it worked. Thank you for the help and guidance.

NOW to learn how to properly repair and or replace the parts.

would you recommend me replace all the components? blower motor & resistor, even if I just replaced the resistor last year with the updated part? and the blower seems to run fine, but from what I gathered is the reason the wire melted in the first place, drawing too much current and creating heat...

do you guys have any recommendation on where to buy?

AND how should I install the new wire, as to prevent this from happening. Solder instead of butt connector, anything else I should know Please let me know.

Thank you so much for the help.

 

I don't think I'd replace anything, the heat was almost certainly caused by a poor connection at the splice, resistance in a circuit that is passing current generates heat.
If you have a clamp-on DC ammeter you could check the current draw of the motor, as long as it's under 20 amps on high it's fine.
I do recommend my relay mod if you use high alot to keep the switch from failing.
https://www.tacomaworld.com/threads...lay-mod-prevent-blower-switch-failure.827331/

Asking what's the best way to splice a wire is kinda like asking what oil to use, everyone has an opinion.

In my opinion from best to worst:

Solder (leaded not lead free) & heatshrink > crimp & seal or ferrule crimp & heatshrink, > non-sealed butt connector > twist n tape > solder seal connector >scotchlock.