F4Gary said: ... So I started feeling wires. Followed the orange wire all the way back to the inline fuse to the horn relay. The orange wire does not get hot. The red wire from the horn relay to the inline fuse is pretty warm, and the inline fuse holder is hot to the touch. Does this tell you electricians anything? There is a 30 amp fuse in the holder.
There HAS to be a draw there somewhere to create that much heat. IF the new blower motor did not lessen the amp draw, then there has to be a bad/corroded connection in that wiring, most
likely place would be the in-line fuse/fuse holder.
The high speed relay gets it's main 12v source from that wire coming from the horn relay. The horn relay on these early cars is basically a junction box, a place to tap into a solid 12v source for other components of the car...the blower being one of those components. Make sure the connection AT the horn relay is clean, and tight. Then follow the wire all the way back to the high speed relay, looking for anything that don't look right...like swelled insulation, or melting. Take a GOOD look at the crimp connections on the in-line fuse holder...if there is any corrosion(green, or white chalky crap) there, that is a source of resistance in the circuit, and that will create heat. As a test, you may want to run a new wire from the horn relay back to the high speed relay, and see if that eliminates the amp draw. If it does not, then the only place left to go would be the alternator, or voltage regulator....
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