HVAC up in smoke (and other problems)

[bobbo]

Hi all. Mys sister owns a 96 Contour GL, and she is having a few problems with her car:

The fan speed knob on her HVAC melted, along with the wire connecter on the back of it... I mean scorch marks and burning electrical smell. We swapped out the old one (and pug) with a new one, and it did the same thing... obviously, the wiring to the HVAC has a short in it someplace. Where's a good place to look?

Her headlights only stay on low-beam... tried new fuses, relays (both on the column and the one under the hood) and a new switch...

Oh, forgot to mention, her ex-bf "worked" on it around the radio, so I'm guessing that would be a good place to look...

Any suggestions, give me a holler,
Bob

 

[Tony2005]

Does the fan not work at all or does it only come on, on "high"? This "new knob", did you get from the dealer or a junk yard. There was a extended warranty on the switch but I think it is over now. But you need to get the new switch. Apparently, it is upgraded and more "robust".

When you put on the high beam, does the low beams go out or does it just stay on low?

 

[FavoriteMystaque]

Definitely get new switch/harness repair kit, check the blower motor resistor too, and the motor itself (not locked up). Schematic may help you. Also, go over that radio wiring for sure!

 

[CSVT_2004]

I would check the radio wiring as well, did the knob melt right after the radio was put in? It sounds like your wire is being shorted out and not fused... Did he use a harness for wiring the radio up, or just hack it off and try to hardwire it?

 

[elraido]

I had the same problem with my 95 before I sold it. The fan speed knob was stuck one day and then a few days later it stopped working. Checked the fuse and it was popped. Took out and replaced the HVAC and the harness for the fan speed was part way melted. Cleaned up the connection on the harness and it has worked fine since. it wasn't until reading this thread that I ever heard about a warrenty for this.

 

[bobbo]

sorry about the late getting back...

Not sure about the hvac, I haven't seen the car since I put the new HVAC in Monday, and she said it was hot to the touch when she drove home. I'll take a peek at it when I go back to town tomorrow.

The headlights stay on low-beam when the switch goes back between high and low beam. It doesn't blink, flash, or dim at all when the lever moves. I don't have the foggiest idea what's going on, unless it's a short. Do the headlight wires run near the radio?

 

[Tony2005]

... Do the headlight wires run near the radio?

The radio and headlight wires all go to a bundle in the fuse box. Maybe, the high beam wires were cut accidentally. In addition, change out Relay 10 (in the Power Distribution Box next to the battery) for a new working one and see if it helps. R10 is the high beam relay. Download an Owners' Manual (free) www.fleet.ford.com.