This time its electrical.. long

[DrDusty86]

I posted a month ago about my blower speed not changing from 3-4. The blue wire with the plug was SMELTED badly. I have replaced that harness. Now the other big fat 5 wire plug is smelting. That one I have to order from the dealer and cut the old connector off and soldier and heat shrink on the new one. I unplugged the connector for the time being. WTH is up with the electrical here? Also my car has developed a random "stumble" between 2k and 2.5k there is not check engine light on or codes. the fuel filter "wix" was replaced 20k miles ago, plugs "factory motor craft" about 15k with wires. The car with this random "[censored]" has surfaced all recently. I'm getting VERY aggravated with it. My dad who lives about an hour and a half from me knows it is my school car and the issues that came up but will not drive down to get and fix the car for me, I'm taking summer classes at the university and I'm so busy I have to schedule time to sleep.
Thanks Dusty

 

[Quest]

what kind of car is this you talking about?

 

[DrDusty86]

my 99' zx2. it is is good shape outside and the interior is excellent, has always had seat covers and bath towels on the carpet. I keep the plastic interior Miguire(ized) They will put a new bumper on the back and the supports when they insurance thing gets settled from when that lady hit me.. Minus the bumper cosmetically is is in near show room condition. But the little things that suddenly have appeared are getting to me.
Dusty

 

[Brons2]

alternator putting out too much voltage?

 

[DrDusty86]

13.8-14v. The connecters also were corroded.. dissimilar metals? which may have led to the high resistance and the melting.. The stumble has me puzzled as well.
Dusty

 

[bullwinkle]

Unfortunately a very common "blue oval" problem-make sure all is bright & shiny when you put it back together, and use some De-Ox or even white lithium grease on the pins when you reassemble it. Silicone sealant on the outside wouldn't hurt either.

 

[2oldtommy]

For the stumble, have you tried some Techron or Regane in the fuel tank. If you haven't run any fuel system cleaners recently, this may be all you need to do. Works for me.FWIW-Oldtommy

 

[motorguy222]

You say that there are no codes,has it been scanned?

Sometimes a code will store in the computer but wont give a check engine light.

The wires that have been burnt,is there any way that they can get wet? Sometimes very small leaks can begin around the windshield that can let small amounts of water seep in.It may be hard to find them but it can happen.

There is also the possibility that you could be getting moisture from the AC if the wires are close to anything to do with it.It wont take a lot of wetness to cause a lot of problems.Just having moisture over a length of time could cause problems and since this is happening now,it might be something to look at.

 

[DrDusty86]

Scanner says "system pass" I do run Techron concentrate every oil change... I posted about my AC not dripping water, but I can't find ANY sign of water or condensation on the floor, carpet, smell, nothing is wet. I don't know, they are BADly corroded and burnt, so i'm thinking dissimilar metals is 90% of the cause. but maybe the moisture from ac, but it must be a drop at most... I will pack the connector with dielectric grease on the harness that I already installed.
UPDATE: the "other" burnt/corroded harness is $270 from ford and only ford # 14401. The dash has to come out to get to the other end of the plug. IT just keeps getting worse.....AARRRGG

 

[motorguy222]

You may be able to get the harness at a junk yard.More than likely the same harness is used on several versions of Ford/Mercury cars.

If there is no water coming from the AC system,it has to be going somewhere and some may be getting into places it shouldnt.You dont need a lot of water to makes things go bad and do it fast.

Some cars have a "hole" in the carpet under the dash where it meets the fire wall,this is where part of the ventilation system goes.Part of the ventilation plenum feeds into where the hole is.If you dont have any condensate outside of the car,there is a possibility that if your car has a similar system,this may be where your water is going.

The condensate could be draining into this part of the system.
After it gets into this area,I dont know what happens to it,there may be some type of chassis drain hole somewhere that lets it out.

 

[sleddriver]

Quote:
... I posted about my AC not dripping water, but I can't find ANY sign of water or condensation on the floor, carpet, smell, nothing is wet.

Pull up some carpet, then the pad, then feel below the pad, against the metal, in the floorboards . . on both sides.
Quote:
I don't know, they are BADly corroded and burnt, so i'm thinking dissimilar metals is 90% of the cause.

The AC drain should be low on the floor. Can't imagine how this harness would be wet from it, unless it's underneath where water could drip on it, run down the wire(s). Corroded joints have higher resistance than clean ones, and with enough current through it, causes them to heat up. If they heat up too much, the insulation melts and so do the plastic connectors.

I suspect your blower motor is going tango uniform.

 

[meep]

^^^echo that^^^ I wonder if the motor is pulling too many amps. bearings starting to seize or the commutator is developing a short in the motor.

DEFINITELY CLEAN and grease those connectors.

FWIW those motors are typically sealed.... but if u drill the rivets can be opened up, cleaned, lubed. use nut/bolt in place of rivets.... be prepared to spend an hour trying to line up the housing halves just right so it will spin freely-- it's a bit of a puzzle, but can be done. or just buy a reman motor.

 

[Eddie]

Sounds like shorted motor windings. Get another motor.

 

[mechtech2]

The connector contacts have to be clean and shiny - no corrosion.
Male and female both.
A small screwdriver with scothbrite, steel wool, sandpaper, etc will help. The fan MAY be drawing too much current - it MAY be faulty.
But check out the wiring first, And make sure your ground is in great shape.

As to the engine, a vacum leak is always possible. The rubber elbow for the PCV valve always goes out on those cars [i have one]. Maybe clean your MAF with spray dedicated MAF cleaner.