Originally posted by big_mack: Best guess is you have a wire connection issue. A bad connection causes high resistance, which in turn results in low voltage to the fan, the fan then draws more amps to compensate which stresses the relay.
This is not possible. Basic Ohm's Law. E=I X R. Applied voltage (to the circuit) is constant at battery voltage. If resistance in the load circuit increases, current must decrease proportionately.
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if the current is too high the fan itself could be bad.
This, on the other hand, is correct. A DECREASE in the load resistance will cause a proportionately larger current flow.
Suggest that the low speed resistor circuit be checked. If that dropping resistor opens, the fans will not engage until the upper trigger temp (around 215-220 F ) is reached. The resistor is physically located on the bottom of the radiator shroud. It has been the subject of several in-depth discussions.
Steve
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