HELP! Melted Connector

"Camshaft Chris: Skyline/McLaren/Porsche Fanboy" (camshaft-chris) 04/18/2016 at 13:43 • Filed to: Ford, Fail, Fix Or Repair Daily, Wiring, Melted, A/C

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This is the wiring harness connector for the A/C motor on my wife’said 2012 Ford Fusion. It’s melted. My guess is that the wires became exposed and overheated the plug and caused it to melt or something. I have no idea if that’s accurate though.

Are there any Ford guys on here that could give me a little more insight have? Is this something I can just fix with a new connector and some electrical tape for additional insulation? Or am I looking at a bigger issue has? Thanks!

MontegoMan562 is a Capri RS Owner > Camshaft Chris: Skyline/McLaren/Porsche Fanboy 04/18/2016 at 13:49

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12 Fusion, what motor? I’ve never heard of something like this happening but the motor size would help.

PartyPooper2012 > Camshaft Chris: Skyline/McLaren/Porsche Fanboy 04/18/2016 at 13:50

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It’s hard to say from where I am sitting - chair... but I would say them two wires connected somehow and shorted you out... do some investigative work and see if some wire crossed streams with another wire. If so, there is your problem. Get new plug. Reconnect them without crossing streams this time and you should be good to go.

Alternatively, your car is new enough, that the dealer might be willing to fix your issue under warranty...Assuming of course you’re first owner.

Option 3 is to install old school AC system - open all windows and don’t use AC. Arm out of the window cools you off additionally.

EDIT: all recommendations are based on assumption you’re a professional electrician. I assume no responsibility for advice as it is my opinion only and does not reflect views of OppositeLock.kinja.com

DrScientist > Camshaft Chris: Skyline/McLaren/Porsche Fanboy 04/18/2016 at 13:54

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dont use electrical tape. bouncing around in your car, the tape and the twisted wire ends will eventually bounce themselves apart.

get a new connector, pick up a soldering iron and some heat shrink tubing. check the youtube for tutorials on how to solder.

get the new connector from a scrap yard, and be sure to cut 5-6 inches of wire with the connector, so you have something to solder to.

also, dont forget which wires went to which pins.

:)

dogisbadob > Camshaft Chris: Skyline/McLaren/Porsche Fanboy 04/18/2016 at 13:57

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jimz > Camshaft Chris: Skyline/McLaren/Porsche Fanboy 04/18/2016 at 14:02

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what do you mean by “A/C motor?” Are you talking about the HVAC blower motor under the dash? or is that the connector for the A/C compressor clutch? Or the fan up by the radiator?

in any case, a short will (hopefully) almost always blow a fuse. When I see that kind of heat damage, I tend to think the motor it’s supplying is drawing too much current. maybe something is overloading/binding the motor.

Takuro Spirit > Camshaft Chris: Skyline/McLaren/Porsche Fanboy 04/18/2016 at 14:06

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Check the resistor as well. If that’s good then just get a new connector (pigtail) from Ford. They probably sell a bunch, as Fords have issues keeping their blower motors from burning up wires.

Scott > Camshaft Chris: Skyline/McLaren/Porsche Fanboy 04/18/2016 at 14:31

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Looks like damage caused by a short circuit. That would lead me to wonder why you did not blow a fuse? It’s already been said, but don’t use electrical tape. Ideally, replace the connector, and pins on the wire, and check out exactly why it shorted. Next best would be to get a new connector with a bit of wire, solder them together and use heat shrink on each wire. Last option would be to use but connectors, and use the electrical tape or better, heat shrink to keep moisture out of it.

Camshaft Chris: Skyline/McLaren/Porsche Fanboy > Scott 04/18/2016 at 14:34

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I didn’t even think about checking the fuses to see why it hadn’t blown. I do that tonight to see if I have too big of a fuse in there. Thanks!

Camshaft Chris: Skyline/McLaren/Porsche Fanboy > DrScientist 04/18/2016 at 15:00

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Yeah, heat shrink tubing does sound like a better option than the tape... And I doubt I’ll be able to find a connector in the scrap yard. The car’s only a 2012. But I’ll call up the local pick-a-part and see. If not, I’ll probably have to go to the local dealership. And yeah, I will definitely check those out on YouTube . I don’t want to cause anymore issues with it, lol. Thanks!

Camshaft Chris: Skyline/McLaren/Porsche Fanboy > dogisbadob 04/18/2016 at 15:03

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Lol, nice. Funny thing is, my ‘97 Crown Vic hasn’t given me any sort of issues like that... Guess they just don’t make ‘em like they used too. :P

dogisbadob > Camshaft Chris: Skyline/McLaren/Porsche Fanboy 04/18/2016 at 15:03

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Even Toyota doesn’t make em like they used to :(

Camshaft Chris: Skyline/McLaren/Porsche Fanboy > Takuro Spirit 04/18/2016 at 15:04

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Will do. Thanks!

And I din’t realize that had a lot of issues with that. Good to know I’m not the only one.

Camshaft Chris: Skyline/McLaren/Porsche Fanboy > MontegoMan562 is a Capri RS Owner 04/18/2016 at 15:04

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2.5L 4cyl.

Camshaft Chris: Skyline/McLaren/Porsche Fanboy > jimz 04/18/2016 at 15:05

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Sorry, yes, it’s the blower motor under the dash.

MontegoMan562 is a Capri RS Owner > Takuro Spirit 04/18/2016 at 15:06

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Never heard of this one either

Takuro Spirit > MontegoMan562 is a Capri RS Owner 04/18/2016 at 15:12

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This car is fairly new, but it wouldn’t surprise me, considering how many older Fords had similar issues.

MontegoMan562 is a Capri RS Owner > Takuro Spirit 04/18/2016 at 15:19

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I mean, I’m driving almost the same car with a Mercury badge and a V6 at 104k miles.

I need to go find some wood to knock on....damn formica desks...

sdwarf36 > Camshaft Chris: Skyline/McLaren/Porsche Fanboy 04/18/2016 at 22:47

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Boy-Ford still hasn’t got this shit fixed. My example is a 97 e-450 diesel van. Seems like any plug that has a fairly hi amp load can have this happen. Corosion builds + makes more resistance. And resistance makes heat-melting plastic. Good thing Ford knows this. Call your dealer-I bet they make a replacement plug for it. I know they did for mine. ( I changed it because it was green + fuzzy-hadn’t melted) Also was able to plug ends for for my speed sensor on the rear-and the main tranny plug-and glow plugs + injectors. Anytime I’ve needed one, Ford stocks it.