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Well, on the way up to FOTB my car started to overheat on the traffic-packed 101 fwy. We all pulled over and checked it out and all seemed alright. No problems until we reached that same area on the way back and it happened a few more times. I opened the hood to inspect again and found that the fans were NOT coming on. We check a few things and all of a sudden they are working again. Great, intermittent failure. Since I don't have my fluke and test equipment with me, we continue on, watching the gauges carefully. I get it home and I suspect that the resistor assy for the fans may have a bad connection. I unplug it to find this:
Apparently the connection may have been poor, causing excessive heat or maybe the resistor pack got too damn hot. Either way, I raced to my local Ford dealer for the resistor assy. and the wiring harness for the fans. They had a new resistor assy., but the harness will be here the next morning. Total cost is $32.00 for the assy. and $60.00 for the harness. Easy fix too. Check your connections. Maybe a little dielectric grease on them too. Here is a pic of the location of said resistor assy. I have circled the area and you can see my temporary fix so that I can get to work tomorrow.
The insulation on the wire was brittle and melting as well as the rear of the plug.


Apparently the connection may have been poor, causing excessive heat or maybe the resistor pack got too damn hot. Either way, I raced to my local Ford dealer for the resistor assy. and the wiring harness for the fans. They had a new resistor assy., but the harness will be here the next morning. Total cost is $32.00 for the assy. and $60.00 for the harness. Easy fix too. Check your connections. Maybe a little dielectric grease on them too. Here is a pic of the location of said resistor assy. I have circled the area and you can see my temporary fix so that I can get to work tomorrow.

The insulation on the wire was brittle and melting as well as the rear of the plug.
