I need a replacement plug for the heater blower relay in my 95 Chevy pickup truck. Everytime I turned on that blower motor lately, I have been smelling a hot sweet smell of something overheated. Shutting off the blower stopped the smell.
The blower motor and associated wiring in these mid 90's trucks are notorious for electrical failures and even some fires. A year ago, my blower stopped working, and I found a plug was melted. I removed it, and soldered the wires together. (That plug was undersized when manufactured, and is the #1 cause of fires). I eliminated it!
Today I ripped the dashboard apart again, and traced the wires. Nothing was burned that I could see. After having a bucket of water handy in case of fire, I left all the wiring exposed and let that blower run. Soon I smelled the hot odor and began sniffing around. The odor was around that same wiring area, and near the blower motor, but the blower itself was not hot, nor was it's feed wire.I left it run longer and the odor got stronger. Eventually I noticed a little smoke, and then the blower stopped. I reached down there and almost burned my hand on the heater relay and one of the wires behind it.
I unplugged the relay, and found one of the five contacts was burned and the plastic around it on both the relay and the plug melted. That exact same sweet smoky odor was very strong on that relay.
The local auto parts stores have the relay. But none of them have the plug. I suppose I could order the whole wiring harness from a Chevy dealer for a huge price, but that's not gonna happen.
We have no auto salvage yards around here. Where can I get a plug?
This is the exact relay: (photo included)
No, I cant use those 1/4" crimp on terminals, these terminals are roughly 1/8".