Its common that the wire harness has melted where it connects to the blower motor resistor. To get to the blower resistor you must take off the modesty panel that
hides all the wiring. The right side of this panel (to the right of the
courtesy lamp) just swings out of the way on a plastic hinge, after you
untuck it from the other side. It does not come all the way off, but
it doesn't need to. After this, the other (larger) section removes with
three screws. (This panel must be reinstalled correctly, because
molded into it was part of the ductwork that routes air up to the
defrost vent on that side. Make note of how it fits before you take it
out.) Lay all this carefully aside where you can find them later,
especially the screws.
Once this is out of the way, the real fun begins. The blower motor is
behind your glove box, partially obstructed by an electronic relay box (BCM). The blower motor relay is behind the blower motor,
jammed up against the firewall. Disconnect the wiring harness from the
resistor and the motor; tuck it out of the way. You should not have to
take the blower motor out to get to the resistor, but if it's in your
way, go ahead. Be careful to move your head out from under the
dash...the blower motor is heavy, and if it falls on your forehead,
you'll have an embarrassing mark to explain to people for about a month. The resistor mounts with two screws.
You can replace the resistor or just replace the wire harness if it's melted which is a common issues after a few years of being heated up from the electrical current running through the wires.
Good luck and keep us posted.
It sounds to me like you have a loose wire
somewhere. A loose wire explains why it sometimes works and sometimes
doesn't. It could easily come loose when hitting bumps and go back in
place when hitting bumps as well. Another thing a loose wire could do is
cause a short... It depends what the problem is exactly... Does it
work sometimes and not work sometimes as soon as the car is turned on?
Meaning, if it's not working when you start the truck, it won't the
entire ride. Or, is it working on and off throughout one full ride?
This should help more with determining what the problem is exactly.
If the light will come on and go off while you're driving, it's going to be a
loose wire. The wire could be bumped in and out of place while driving,
which is why it works and stops working while driving. It could also be a
worn wire that's being bumped together and apart, causing the same problem.
So check the wires going to the headlight set up.
If the light works sometimes when you start your truck and sometimes doesn't,
but doesn't change while driving, it could be a short. It could also be a
short if your light it working when you start driving, but eventually turns off
while driving, but never goes from OFF to ON. This is because if there's
a short, you would have to turn the truck off and then back on for the light to
possibly work again. With a short, the light will NOT come back on while
driving if it was not working when you started your truck. If it's a
short, you're going to have to figure out what's causing it. They have
tools you can buy for that. There are basic ones for roughly $25-$30, but
I believe those only test one wire at a time. While there are other ones
which can easily run $150 and more, and those test all the electrical at once
and tell you where the problem is.
Your best bet is to check the wiring involved with the head light set up.
If you notice any loose wires or old wires that are starting to corrode
or crack, replace them and that should do the trick! If you don't notice
anything, you could purchase one of those tools and test for a short. Or,
what I recommend instead of buying the tool is take your truck to your local
auto parts store (AutoZone, Pep Boys, Etc) and tell them what's going on, and
ask them if they could test the truck for a short. Then, if you don't
want them to fix it, just tell them you needed a quote and you'll come back
when you have money... and then just do it yourself. Or, you could have
them do it if that's what you prefer...
Good Luck and I hope I helped!!
Brendon
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