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Burnt wires on ignition switch

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Old 06-14-2011, 01:31 PM
mlott132 mlott132 is offline
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Default Burnt wires on ignition switch

My dads blower motor stopped working on his 04 1500. I found that there are two wires, red and blue, towards the top of the ignition switch connector that look burnt. About a half inch of insulation has also melted off of both these wires. I am going to replace the ignition switch as it looks to be burnt as well. Anyone know what is causing this issue and is there a perminant fix? I found a picture in another thread that matches what the burnt wires look like.

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Last edited by mlott132; 06-14-2011 at 01:34 PM.. Reason: Added picture
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Old 06-14-2011, 02:33 PM
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Ok, with the black top of the switch facing up, pins 1 and 8 are at the top.

Pin 1 is a 10ga red wire that is a direct battery feed. It should have 12v at all times. It is a wire from the battery feed circuits.

Pin 8 is a 10ga dark blue wire and supplies 12v to the fan blower motor. It is a wire from the climate control circuits.

So it seems likely you are pulling too many amps through that circuit for the blower motor. This could be many reasons such as a motor going bad, poor ground or loose connection. It could also be none of the above but rather too small wire for the circuit. IDK what the engineering specs called for on that circuit.

But that should cover your Qs. Feel free to ask more if needed
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Old 06-14-2011, 03:35 PM
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What is the amp draw of the blower motor? I am thinking of installing an inline fuse to prevent this from happening again.
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Old 06-14-2011, 06:04 PM
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is the plug burnt or have any corrosion. also look at the pins on the switch for the same thing. Improper contact(loose/corroded connection) will cause heat build up and burn the wires. When i replaced mine i found a wireharness from a junk yard and spliced in a new plug.
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Old 06-14-2011, 06:37 PM
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Yes both the plug and switch have burn marks on the same terminal. Does not appear to be any corrosion, so it looks like a bad connection. I am going to try to take the connector apart to see if I can clean the terminals on the plug. I am also going to cut the bad section of wires out and reconnect. Hopefully that will fix the problem for good.
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Old 06-14-2011, 08:20 PM
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Anyone know what the part number is for the connector plug that goes into the ignition switch? Are these available through the dealer or just at the boneyard?
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Old 06-14-2011, 08:34 PM
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good luck no one had the connector nor could they get the connector. i was lucky and found the whole wire harness that goes under the dash for 20 bucks at a junkyard.
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Old 06-14-2011, 11:08 PM
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There was a tsb on the 02's for the gauge of the wire, did that extend to any other years?

Just wondering if a dealer could fix it under that for no charge.
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Old 06-15-2011, 09:30 AM
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Quote:
Originally Posted by mlott132 View Post
What is the amp draw of the blower motor? I am thinking of installing an inline fuse to prevent this from happening again.
Again, thats apart of the engineering specs that Im not sure what they are and therefore cant determine the rest of the circuit load

Quote:
Originally Posted by mlott132 View Post
Anyone know what the part number is for the connector plug that goes into the ignition switch? Are these available through the dealer or just at the boneyard?
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Old 01-08-2012, 10:06 AM
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Quote:
Originally Posted by Owensue View Post
There was a tsb on the 02's for the gauge of the wire, did that extend to any other years?

Just wondering if a dealer could fix it under that for no charge.

Already tried that route by calling the dealer themselves. They said I would have to pay for it since anything over 02 is not covered under the TSB recall. They would not sell the part to me because it was a recall item. I am working to get this covered under the TSB, but if I can't make it happen, I will just have make an overlay harness myself when I go home on leave.
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Old 01-08-2012, 10:06 AM
 
 
 
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