Replacement blower fan switch connector has thinner wires

[TheYonderGod]

The brown wire is the one that melted and caused me to replace the switch and connector. I ordered a replacement and I just noticed that the wire in that spot is thinner than the rest! If I use this it's going to melt again even faster?

Should I just use individual spade terminals? That would also get rid of an extra splice on each wire...

 

[macleanflood]

Could just use it to trigger a relay

-Mac

 

[TheYonderGod]

Could just use it to trigger a relay

-Mac

I saw that thread but I didn't understand it so I was just gonna do it this way for now until it happens again when I hopefully don't have 100 other things to do

 

[B1Toad]

Assuming that's the correct one for your Jeep it would appear that they didn't assemble it correctly. You can de pin the connector using a small tool like a Jewelers screwdriver and swap the wires around. In your pic, moving clockwise starting at the the brown/tan wire is for high and needs to be AWG 12, clockwise next is light blue for medium speed 2 and needs to be AWG 14, next is light green/light blue stripe for medium speed 1 and can be 16 AWG, next is the white wire for low speed and can be AWG 16 and finally is the dark green supply wire which needs to be AWG 12.

In summary, the two fattest wires need to be blower high and blower motor feed, the next fattest for blower medium speed 2 and the skinny wires to blower speed medium 1 and blower speed low. Looking at it from here it looks like you may only need to swap two of them, the top left with the one diagonally across from it. It looks like they only used 2 sizes.

 

[TheYonderGod]

Assuming that's the correct one for your Jeep it would appear that they didn't assemble it correctly. You can de pin the connector using a small tool like a Jewelers screwdriver and swap the wires around. In your pic, moving clockwise starting at the the brown/tan wire is for high and needs to be AWG 12, clockwise next is light blue for medium speed 2 and needs to be AWG 14, next is light green/light blue stripe for medium speed 1 and can be 16 AWG, next is the white wire for low speed and can be AWG 16 and finally is the dark green supply wire which needs to be AWG 12.

In summary, the two fattest wires need to be blower high and blower motor feed, the next fattest for blower medium speed 2 and the skinny wires to blower speed medium 1 and blower speed low. Looking at it from here it looks like you may only need to swap two of them, the top left with the one diagonally across from it. It looks like they only used 2 sizes.


View attachment 567149

Thanks, you're right. Depinning was my first idea but seemed impossible without ruining it. After I read your reply I took another look and I realized the whole side of the plug snaps open, which made it a lot easier.




I did already wire it up with individual spade connectors because I was impatient waiting for replies It works but I do have slight concerns of the wires vibrating loose or the pins bending and touching each other over time, so I'll put the new plug on soon.



Edit: Wow, I've never seen this before, I am actually impressed with Rockauto's automated customer service. I expected them to say no refund if I don't return it, but I got a refund for telling them I was able to repair it.