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Blower inop among other things


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Good evening to all I hope you have your favorite beverage and snack for this one as I've gone down a deep rabbit hole trying to bring this truck back to life so here we go!

 

                     -----Short story, if you are having blower issues and the troubleshooting has basically stopped check the interior fuse panel to ensure you are getting good contact with your fuse, having an add-a-fuse can spread the little keepers inside the fuse holder creating an interrupt at the ignition source for the blower relay (pin 86 I believe).--------

 

In the process of fixing one of the numerous issues with my recently purchased 2001 Cummins I was at that moment in time where you are ready to fire up the rig after doing some work in hopes it kicks over with no issues and noticed my fan blower is not turning on. I kept my eye on the prize and decided I would circle around to that issue once I conduct a leak check for the timing cover and crank seal I just removed and reinstalled. Everything went well and later replaced the oil pan gasket as well, hopefully no more leaks once the truck is running again....more about that soon.

 

I started to dive into the fan checking the simple things like relays, fuses, and connections as within the past month I put a new blower and resistor in. With no luck I turned to the forums which lead me to an ignition switch. A quick trip to the parts store and they had one in stock luck me, swapped it out and again nothing changed with the blower motor, time to investigate further.

 

This is where things get deep, I started looking under the dash as any typical person would looking for some "obvious" sign that said your problem is right here but instead I found a wiring harness that has multiple grounds shorted and burned through casing and even melting some plastic. :mad: the blower issue was a blessing in disguise as I feel my truck would have burned down eventually. 

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So at this point it was off to the races with the dash removal and figuring out what to do next. Naturally the heater box came out as well, I went ahead and replaced the heater core and A/C evap cleaning out the box to remove all the nasty stuff built up over the years. That's when I discovered what I can only assume to be factory splices, can someone confirm this for me it's on the passengers side as well. Full disclosure my truck was hit on the drivers side and the PO rebuilt the truck to some degree hence all my issues (you live and you learn) which is why I believe there is a lot of bondo in these areas just weird to see it on the passanger side as well in the same spot, again maybe it's OEM?

 

                                                 DRIVER SIDE                                                                                                                               PASSENGER SIDE

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I've been able to source a new harness via Ebay and everything has hooked back up nicely. I went down the entire trouble shooting steps alldatadiy.com provides and had multiple Schematics printed so I could check all wires within the blower system finally resulting in a loose fitting fuse for the blower motor in the fuse box. :doh: the PO had some crazy electrical things going on with this truck to include a crappy Add-a-Fuse which basically widened the holder for one side of the prongs that hold the fuse in place. But my blower works now and that's a huge weight off my shoulders plus some confidence building on my part as electrical has never been my strong suite.

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So I finally figured this one out and now it's onto the next steps of getting this truck on the road. I'll be taking it to a body shop this week hopefully to get the door aligned/checked out, body work is beyond my skill level and the truck is constantly leaking water (didn't figure this out till after purchase, go figure). Leaks are coming from the half doors on both sides and I've already replaced every seal I can get my hands on. It's also leaking in the corner of the windshield where the VIN stamp is riveted on the truck, I believe the PO allowed a "buddy" to install the window instead of a trained professional so that will get fixed as well.

 

To round out this long post I have literally the entire truck stripped right now waiting to have sound proofing/deading installed, brand new carpet, headliner, and sun visors, completely new dash and whatever else I have sitting around waiting to be installed. Should be basically a new truck at that point :pray:

 

I'm also waiting on my new GX-E 57/65/14 from @dieselautopower to show up so it can get that thrown on once it returns from the body shop!!! Phew that was a lot to write but I appreciate all the help from this forum over the past month. I am hopeful that when it's put back together my electrical issues will subside and I can work on getting my Quad talking to the ECM etc. but that's for another day. Cheers!

 

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I thought it was just me when I bought my truck and had to replace part of the dash harness, all the wires melted together on the steering column and by the brake pedal so that was a joy. 

 

But I second the sound/heat insulation! Quiets down the cab a fair amount and makes in vehicle calls a lot easier.

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On 5/11/2020 at 8:08 AM, dieselautopower said:

Thank you for the nice write up.

 

While you have everything out you may want to add some sound insulation to the back wall to add some mass and dampen some of the noise.

 

 

 

On 5/11/2020 at 9:38 AM, Towrigdually said:

I thought it was just me when I bought my truck and had to replace part of the dash harness, all the wires melted together on the steering column and by the brake pedal so that was a joy. 

 

But I second the sound/heat insulation! Quiets down the cab a fair amount and makes in vehicle calls a lot easier.


 

that’s my intent and the reason I decided to just tear every piece of interior out. I have quite a bit of sound insulation to reinstall when I get it back from the body shop. I also plan to run new speaker wire to all the doors/tweeter along with amp wire for the anticipation of a new sound system down the road. 

 

I found the issue with my blower motor finally! There was no actual issue with any of the HVAC components and all wires/grounds are in good condition. The issue ended up being a loose fitting fuse in the AUX fuse panel when you open the drivers door. The PO had all sort of "add-a-fuse" prongs so when i removed them the fan blower fuse was not making contact with the little holders inside the panel. I've replaced the fuse with a brand new one that has some more material on it so it maintains a solid contact.

 

Edited by jtrakel
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