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Help troubleshooting blower motor issues

Discussion in '2nd Gen. Tacomas (2005-2015)' started by ides98, Jul 11, 2017.

  1. Jul 11, 2017 at 5:06 PM
    #1
    ides98

    ides98 [OP] Active Member

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    I've seen there's been lots of reported issues with blower motor related parts. I had a burning smell every once in a while when running the air on high speed for a while so only ran at lower speeds. Then recently I had intermittent use of lower settings with high setting not affected. This week I replaced both the blower motor connector (which was visibly melted/burned) and the resistor. I also noticed the resistor plug has some charred spots so getting ready to replace it. However I decided to unplug the resistor plug and drive around with air on high. There is a burning smell that has returned. So it seems I have/had two separate issues with the resistor causing intermittent use of lower settings and then this burning smell when run on high. Any ideas on how to troubleshoot this other problem to know what's burning on high setting? Should I take the blower motor out and clean it? Or any other common problems. Thanks, it's gotten damn hot and it'd be great to have air. Sweltering right now. Appreciate any one's thoughts.
     
  2. Jul 11, 2017 at 6:30 PM
    #2
    Bocsy44

    Bocsy44 Well-Known Member

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    This that and the other thing.
    check your connectors at the switches them selfs, if you have bad connections at the switch it will increase the resistance which will cause burn outs.
     
  3. Jul 11, 2017 at 6:39 PM
    #3
    ides98

    ides98 [OP] Active Member

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    Thank you. I will try to find someone who can look at that too. Now that you mention it, one side of the seek buttons on the radio isn't working -- any possibility of being related or just a coincidence?

     
  4. Jul 11, 2017 at 6:41 PM
    #4
    Bocsy44

    Bocsy44 Well-Known Member

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    This that and the other thing.
    I doubt its related, but checking the connectors behind the ac controls is a good place to start, its really not hard to check, the entire a controls just pop out of the dash. a lot of people have had to replace all the connectors and what not so part numbers are on here some where if you look haha
     
  5. Jul 11, 2017 at 6:44 PM
    #5
    ides98

    ides98 [OP] Active Member

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    Great thank you. I'm just learning as things go wrong. Why do you think there are so many issues related to blower motor and such? Just curious.
     
  6. Jul 11, 2017 at 6:57 PM
    #6
    Bocsy44

    Bocsy44 Well-Known Member

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    This that and the other thing.
    from what I have gathered its a loose pin in one of the connectors, and it goes down hill from there. some people catch it early enough and bend the pin to make better contact, some have tried die electric grease as well. if your motor starts making an annoying clicking sound its time for a new one haha I haven't had any burnt connectors, but I did have to replace my motor haha
     
  7. Jul 11, 2017 at 7:38 PM
    #7
    ides98

    ides98 [OP] Active Member

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    I really appreciate your time. Never thought one little thing like that could cause so much issue and money. I'll check it out tomorrow.
     
  8. Jul 12, 2017 at 12:59 PM
    #8
    ides98

    ides98 [OP] Active Member

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    Control panel connectors look fine but that was an easy thing to check for sure. I'll keep troubleshooting.
     
  9. Jul 15, 2017 at 5:51 AM
    #9
    ides98

    ides98 [OP] Active Member

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    @Bocsy44 could the blower motor itself be pulling too much ampage and overheating the connector and resistor/plug?

    Also is there any possibility that there could be something else like a volt regulator or some circuitry component elsewhere in the truck that has failed and can cause this issue?

    My truck wouldn't start up this morning (no turnover but there's a new battery and no lights left on) and I have noticed a burning smell on the drivers side now (just a few times). It eventually started after a while and taking it to check codes now. I'm probably just being paranoid but I have kept this truck in good shape and weird that other things are now occurring.
     
  10. Jul 15, 2017 at 6:21 AM
    #10
    ides98

    ides98 [OP] Active Member

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    fyi the code said too low or high battery voltage and on a battery check the voltage regulator said failed so they said I need a new alternator. Could that be linked to blower motor or just a coincidence?

     
  11. Jul 15, 2017 at 10:21 AM
    #11
    Chuy

    Chuy Well-Known Member

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    2.5 inch lift; 5100's front; OME rear; Air Lift; dual batteries; Bestop bed cover; Nfab nerf steps; EBC rotors; Threadwright Claw MT tires; hood scoop LED light install.
    My blower problem included the connector at the blower. The pins are small, I think .187". I re-wired it with bigger AWG wiring from blower and about 10" of OEM wiring. My third-speed blower setting is intermitten but I no longer have a problem with the high setting. I uploaded pics on another blower thread; if I find them, I'll post them.
     
  12. Jul 15, 2017 at 10:29 AM
    #12
    Chuy

    Chuy Well-Known Member

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    Found pics. Had a difficult time removing connector from blower; it was melted in place. Had to cut off the wiring and take blower to my work bench to remove the connector.

    [​IMG]


    [​IMG]
     
  13. Jul 15, 2017 at 2:26 PM
    #13
    Tex-Tac

    Tex-Tac Well-Known Member

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    Installed Overhead Compass and Temperature Display along with outside temperature sensor and wiring; LED lights reverse backup; LED license plate lights; Added GTA Bluetooth Audio kit to stock radio for iphone audio; Spare tire steel braided air hose extension connection to rear bumper; Installed new headlights along with new bulbs PIAA H4 XTreme and for fog lights PIAA H10 XTreme bulbs. Installed new hood with "hood-scoop". Installed Predator Side Steps. Replaced front chrome grill with customized color matched (Desert Sand Mica) grill with added TOYOTA lettering (also in matched color), installed and secured tailgate anti-theft devices. Also installed a new external TPMS monitor for all 4 tires.
  14. Jul 15, 2017 at 8:44 PM
    #14
    Jimmyh

    Jimmyh Well-Known Member

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    That has nothing to do with current levels or voltage output from the alternator regulator. That is from the heat generated at the connector itself. Loose and sloppy terminal connections have a high resistance that acts like a heater and the result is as you pictured above localized burning.

    If it was an over current issue in general the entire wire would be melted as such and not just localized burning.

    <<<< 40 + years as an electrician / electronics tech.
     
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  15. Jul 15, 2017 at 10:37 PM
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    ides98

    ides98 [OP] Active Member

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    @Jimmyh thanks but that's not my pictures or post. I had no melting on connector plug area just evidence of overheating on the connector wires and then on the resistor plug also.

     
  16. Jul 16, 2017 at 12:17 AM
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    Jimmyh

    Jimmyh Well-Known Member

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    The same facts remain. If the heating is localized it is a localized problem. These blower connectors on the Tacoma are noted for the loose fitting terminals. If the regulator was outputting enough voltage to cause burning connectors it would effect a lot more than just the blower wires and the burning would be the entire length of the wire not just the terminals and connector. A loose connection will have a higher resistance to current ( less amperage draw ), but will generate more heat. That is why the fuse doesn't blow less current, more heat.

    See Ohms Law. http://www.hamuniverse.com/ohmslaw.html

    Just trying to clarify the difference between an over current failure and a loose connection. Take it or leave it your choice. I've been doing this Electrical / Electronics thing professionally in excess of 40 years.
     
  17. Jul 16, 2017 at 8:18 AM
    #17
    juliusjammer

    juliusjammer Active Member

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    I have the same issue. Noticed my harness starting to look burned. If it is bumped it will loose connection. What is the best way to fix? Die Electrode Grease?
     
  18. Jul 16, 2017 at 10:30 AM
    #18
    ides98

    ides98 [OP] Active Member

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    Totally get what you are saying and wasn't doubting you. That makes sense. Just curious to see if other electrical issues I am having could be connected to ensure fixing the problem instead of replacing parts that are going to melt again. Thanks for everyone's responses.

    I will treat the voltage regulator issue separate than the blower motor issue. For the blower motor, even though I replaced the connector and wires that were burned (connector area on blower motor is not burned and in good shape) there is still a burning smell/wires get really hot on high setting with resistor disconnected to eliminate that as problem. (I have replaced resistor too and plug that is showing burn marks.) Also connectors at air control panel look good. So it must be the blower motor itself and guessing I need to replace it.

     
  19. Jul 16, 2017 at 2:34 PM
    #19
    Jimmyh

    Jimmyh Well-Known Member

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    Dielectric grease will make the issue worse as it doesn't conduct electrical current. It is not meant for contacts, but is used for seals on electrical connectors to keep out moisture.

    You may need both connectors or only one check them both. Below is the parts and part numbers of what is needed to repair both.

    Part number 90980-10916 Connector

    Part Number 82998-12380 Wire and terminal

    Not sold as a kit, sold as each. So you will need one of the plugs and two of the terminal and wires.

    Connector:


    [​IMG]


    Terminals:

    [​IMG]

    You may also have a burned resistor connector and may need these:

    Plug Number 82141-04M40
    Resistor Number 87138-04052

    [​IMG]
     
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  20. Jul 23, 2017 at 4:40 PM
    #20
    ides98

    ides98 [OP] Active Member

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    Just had to share an update. My blower motor is filthy and an ant colony had set up shop in there at some point. I assume this is what has been causing the blower motor to pull more power and fried all the connectors. Going to try cleaning it out or replacing it and hopefully that will solve the issue. Mother Nature is amazing but a mother f@&!er some times.
     

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