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Old 06-04-2018, 08:32 AM   #1
dcon9999
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Default Baked plug

Pulled my radio this weekend and came across melted/burnt plug and back of my blower knob.

Anyone ever seen this?




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Old 06-04-2018, 09:32 AM   #2
Charlie-III
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Not in a Subaru, but some GM's and Hyundais.
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Old 06-04-2018, 02:24 PM   #3
Cougar4
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There have been some others here that have had the same issue. The trouble can be due a couple of things. Either the terminal connections were loose or the motor has a problem and is drawing too much current. I think normal current draw is around 7 amps on HIGH. Make sure that the current draw is within normal limits so another set of contacts doesn't get damaged.
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Old 06-05-2018, 12:46 PM   #4
mrsaturn7085
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I've seen this on a few mid-2000s Subaru blower motor plugs before. Never really spent time trying to fix it - cause is excessive current draw and/or arcing on a loose/corroded connection, as Cougar4 said above.
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Old 07-18-2018, 11:18 PM   #5
dcon9999
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Thanks cougar. Will do. My blower motor is actually a dealer replaced one under warranty a few years back...so makes me suspicious. Thanks again
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Old 07-19-2018, 04:08 AM   #6
CosmoTheCat
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I'd wager that female spade is loose, but that's just me. But yeah, I've seen it before.

You see it a lot on GM headlight connectors.
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Old 07-19-2018, 09:43 AM   #7
dcon9999
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It ended up dying on me 3 weeks ago completely. the speed 4 stopped working and then recirculate was doing some funky stuff. Found a replacement ac control at a local junk yard for $45 and got them to throw in the plugs

wired new harness plug and its working great. I planned on checking it in another month to see where we were at.

I think there was definitely some arcing going on. The heat melted the insultation off the wire and caused some plastic burning smell toward the end, but the multi meter is an easy check as well for the 7amps.
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Old 07-24-2022, 10:09 AM   #8
dcon9999
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Wow. This looks familiar....75k later and the replacement died the same way. Went a bit heavy with some dielectric this time around...these parts are getting harder to find/more expensive $100 this time around...




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Old 07-24-2022, 04:20 PM   #9
Cougar4
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Sorry to hear you are having the same trouble again. The problem may be with the blower motor itself. It may be drawing more current than it should be normally. You should have the current draw checked for the motor. If the current draw of the motor is normal you could add a relay circuit that would bypass the motor current through the switch. The switch would then just activate the relay coil, which draws very little current. The added relay contacts would handle the motor current.
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Old 07-25-2022, 12:41 PM   #10
dcon9999
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Thanks Cougar4 - I'll likely multimeter is next weekend. Ultimately, the fan motor/fan died this past winter - so new (OEM) fan motor in there that may or may not cause a problem. That said, my current fan switch died because it got stuck on fan 4 - so thinking it was enough current/arching to fuse into a specific spot on the resistance dial on my last use - I had to forcefully turn it down and then couldn't get fan 4 to work again. In buying a new climate control panel - junk yard included a harness and it definitely has some light discoloration - NOTHING compared to what I had though. So, I'm wondering if its more common that not. I've had that panel on and off at least 50+ times over the years for radio mods so I observe it often - but for others, there's little reason to take it off.

That said - bypass idea is a decent one. I'll likely set an alarm on my phone for a year from now - see how it looks - and if its progressing, I'll likely go that route. Doesn't seem like there is any other oem/aftermarket replacement options.

Thanks.
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Old 07-25-2022, 12:42 PM   #11
AcquaCow
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Blower motor and/or resistor pack are on their way out. Just swap both.
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Old 07-27-2022, 07:09 AM   #12
Cougar4
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There have been a number of folks here with complaints about this issue. I feel it is a design problem. I you are going to try the OEM design again make sure those contacts are very clean and make good solid contact with the mating terminal. I would install the bypass circuit if I was doing this repair. It is frustrating to keep repairing the same problem that keeps occurring over time.
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