I posted a few threads concerning my aux. fans: they were not working. Relay was good, fans were pk, pre-resistor was fine BUT the wires to and from the pre-resistor for the fans were BURNED UP!!! So, I "fixed" the burned wires by putting in about 6 inches of new wire to the resistor and soldering them in and just replacing the burned parts in the wires. Voila! My fans come on now!!! BUT... after about 20 minutes of the fans on, the new wire that I put in started getting really hot and smoking, so I turned the car off. What can cause this? The new wire I put in was the same gauge as the old stuff, so I don't think thats the problem. Could the resistor be going bad (it seems ok now) or do I maybe have a short somewhere, or what? I am driving the car 1200 miles Tuesday and need this to work!

Thanks...Peter

This is caused by an excessive amp draw. I would suspect a fan problem but wait for one of the techs to respond.

The wires should take all the current that the fuse can stand. The usual reason for the wiring to burn at the resistor is heat buildup when the attaching screw is corroded or loose.

Steve...

The contacts where the wires are bolted to the resistor are rusted to hell...so much as to where I couldnt remove the nuts. Do you recommend I replace the whole resistor and the nuts? I figured this was going to give me problems but it's Saturday and the dealer is closed, so I tried it anyway.

Thanks lots!!! Peter

Yes, you will probably need to replace the resistor. The connection that is heating up will probably not be reusable.