my two speed radiator fan quit and i replaced it with a single speed fan from a 1986. I also added a manual switch splicing into the green/white wire and running the switch to a ground. The switch gets very when i use it. Not sure what's going on as i used 14 gauge wire to ground, which seems to be more than the green/wht. Could it be the newer fan draws more than the old 2 speed.
Quit running the full load thru that switch. good way to burn your car down. go buy a 30amp relay and wire that up. it will keep the load off the switch. As with + /- also carrys a load . relays are used to carry that load. by splicing your switch in you are now carring that load inside the car. ...ie hot and warm wires, hot or warm switch, funny burning smells, next is fire. your factory system uses relays for a reason, should you decide to alter that, you should also add relays. Please rewire that! just trying to save ya car man! .
[This message has been edited by dematrix86gt (edited 08-10-2013).]
As i understood it, the green/white splice is a manual trip that closes the radiator fan relay located in front of the driver's headlight, which is what the temp sender does. There should not be much of a load coming thru that wire. And yeah, not using it until I figure out what is going on.
You need to see how many amps its pulling. if you dont have a amp meter you can crudely make one up using a fuse holder . put small fuses in till you find the aprox. amp. that keeps from blowing fuses. then check switch amp rating. but yes dont use it until you find your heating issue.
First of all, the green/white wire doesn't power the fan. It only activates the relay. I don't remember the exact power draw of the relay coil, but I think it's under an Amp. If your manual switch is getting hot, its power rating must be pretty low.
That said, why not just use a low-temp fan switch? Rodney Dickman sells fan switches that will kick on at a more reasonable temperature. No funky wiring mods necessary.
I wanted the option of turning the fan on when I wanted to. Thought this would be an easy way to do that, and it is. Just not liking the hot switch. Found out it is not only the switch getting hot, but the wire as well. So I seem to have a problem with the relay, if it is drawing back thru the relay ground wire. Thanks for the help.
Pulled apart the fan relay and it is a mess, surprised it worked at all. I have only been able to find the w/o AC relay. It seems like I read somewhere on the forum that two of these can be used with some wiring modifications. I'll find it in search archive. Thanks for the help.