I need some ideas why my e-fan wiring would be getting so hot. Hayden fan and control module from Pep boys. Dual fan setup. It appears I have wired it correctly but the wiring is heating up way too hot! It sometimes causes controller to stick in on position even after engine is off. Any one have any ideas b4 I fork over bucks for mechanic?
Thnx

 

use a bigger wire, alot of kits for anything from fans to lights come with wire thats to small. the smaller wire heats up more for a given amperage then a bigger wire. so get a bigger wire setup and a better controller, yours probably cant handle the amperage that your fans are pulling

 

10 gauge minimum for feed and return using 2 fans. I run 12 gauge to each individual fan as well, for the initial startup spikes.

 

Also make sure you do the grounds too. The shorter and larger the wire the better.

 

Sorry, should have specified, all wires to and from fans are 12 gauge.

 

+1 for the wire gauges. 10 for the power source wire from the battery, 12 (or 10) for everything else.

 

thanks for the info. what about the leads for the ac and the ignition source(I hooked mine to the wiper motors)? These leads are very small(not sure of guage)

 

those leads don't need to be as big since they don't carry near the current. 16-18 AWG will usually be completely adequate for the control side wiring if it's only driving one or two relay coils.

 

Those are trigger wires only, not feeding current to the controller. Small gauge acceptable for those.

 

thanks for all the input
OK yesterday I replaced + power lead to battery with 10ga and from controller to fuses w/ 10ga.
Fans are hotter than hell! I think they have 14-16ga lead wires. Should I rewire the fan with 10ga ?