Hey Mattel- The white stuff is some sort of ceramic to hold the coils from vibrating and fatiguing to failure (though that is what eventually happens anyway). The butt connector is a butt splice (in my parlance) and the inner piece is just too long to crimp the coils into. Get a terminal (ring, spade, or disconnect) for the smallest gauge wire that you can (smaller= larger #-- i.e.24ga is smaller than 10ga) twist the insulator(the colored plastic) off of the terminal you bought, and then using diagonal cutters, lop the terminal from the piece that the wire goes into-(looks tubular-that's what you need to keep). I use a very small pair of slip joint pliers that look like channel locks(see pic)-they're only about 5" long- and put BOTH broken ends of the coil through the tubular piece from the terminal so that they overlap. Then, using the very tips of the pliers across the tube, crush the stuffing out of the tubular piece. if you can't pull them out, then it's about as good as it'll get.- You can test it by plugging it in but not putting it back in its hole, and turning the fan on.
Since the circuit runs through the smallest of the coils on any setting but high, if you have an open in that coil, then the circuit never is complete. Likewise, if you have an open in the second coil, the lowest and next to lowest won't work etc. etc.
Xirdneh- I think you've got an open in the middle coil that's resulting in no lower speeds. Its odd that the high speed won't work, you might check the heater relay- The resistor pack is a set of shunt resistors (ie it eats up the power so that the fan doesn't have full current) if you check the FSM, the heater relay supplies the full speed connection for the fan. When the relay is stuck open, everything should work BUT high speed [EDIT Wrong! relay is the first resistor in the circuit Cross A-7 in the wiring diagram]- I use an ohmmeter to figure out which coil is broken if I can't see the fracture.
Good Luck Guys, my fan works, but it's not putting out much heat-it's 1°F here at 2 pm and sunny today.
Can anyone open the gif file? It doesn't seem to work for me-I can try to put it in as a jpg if I have to....
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Last edited by Highlander
on Mon Dec 15, 2008 10:22 pm, edited 1 time in total.
'83 SR5-299K, -tRusty!
'85 SR5-285K-- GOLD-New engine!
'85 SR5-238K -- Teal-Killed by a DD
'58 and '62 Austin-Healey Sprites