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2002 Zetec Cooling Fan Resistor (Need help)

611 Views 4 Replies 3 Participants Last post by  Paul1958
I have replaced the cooling fan resistor 3 times since I have owned this car (160k miles) and it melted once again. My issue this time is that I had to cut so deep to find clean wire to splice, that it is now too short to splice without cutting into the joint where it crosses with the fan motor wires. I am talking about where the wire meets with the other wires that are protected by the black plastic shield, assuming to protect the wires from the cat heat. I am trying not to cut too much as i don't want to damage the other wires and the wire protector. I could easily just order another resistor kit, but I still cannot splice the wires with them being so short and deep into the engine bay. Anyone else been in this situation? Maybe I need to just get it towed. What about a bypass to keep the fan going, so I can at least get it to a shop?
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For the repair you need to do I would highly recommend that you remove the entire electric fan/harness assembly from the vehicle. It is fairly easy to do as there are only two connectors from the fan harness to the under hood harness and the fan itself simply hangs and is retained by clips that are part of the radiator and is removed from under the vehicle. With the fan out you will have better access to the fan harness either for repair or replacement. Here is the fan assembly/harness from my 2005 but the earlier models are essentially the same (click for larger pic):

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BTW the 'corrugated tubing' is usually referred to as harness split loom, harness loom, split loom, etc.

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