Intermittent loss of front blower motor

[craig72]

Hey gang,
We have a 2016 Exped Platinum. The other day, my wife said the front AC blower stopped working. Back air was fine. After reading into it, it sounds like there is an issue with the blower motor switch (YH-1829) and/or the connector to that switch (WPT688). I've even read that a few have caught fire. I dropped the glove box and looked at the connector. Nothing looked melted. However, after disconnecting and reconnecting, the blower started working.
Here is the rub though. When the fan was running full blast, that wire harness got so hot that I couldn't even keep my hands on it. All within about 30 seconds. Turned off AC, temp went down. Back on, temp back up. If I ran the fan at a moderate speed, it got warm, but not super hot.
Does this indicate a problem with the switch or the harness itself? Its going into the dealer since we have a bit of Certified Pre-Owned warranty remaining, but I'm curious about what could be the cause.
Thanks!

​

 

[mjp2]

It's the harness. Mine didn't look burnt or melted until I took it out of the truck and got a really good look at it. Next time it stops working have your passenger kick under the glove box. If it starts working you know you've found the issue.

 

[Don Hall]

"When the fan was running full blast, that wire harness got so hot that I couldn't even keep my hands on it."

I think you have located your problem.

 

[99WhiteC5Coupe]

Hey gang,
We have a 2016 Exped Platinum. The other day, my wife said the front AC blower stopped working. Back air was fine. After reading into it, it sounds like there is an issue with the blower motor switch (YH-1829) and/or the connector to that switch (WPT688). I've even read that a few have caught fire. I dropped the glove box and looked at the connector. Nothing looked melted. However, after disconnecting and reconnecting, the blower started working.
Here is the rub though. When the fan was running full blast, that wire harness got so hot that I couldn't even keep my hands on it. All within about 30 seconds. Turned off AC, temp went down. Back on, temp back up. If I ran the fan at a moderate speed, it got warm, but not super hot.
Does this indicate a problem with the switch or the harness itself? Its going into the dealer since we have a bit of Certified Pre-Owned warranty remaining, but I'm curious about what could be the cause.
Thanks!

​

https://static.nhtsa.gov/odi/tsbs/2019/MC-10163573-0001.pdf

 

[craig72]

Thanks guys. I was not sure if the controller itself was the issue, or just the harness connector. Sounds like its not making good connction, causing the heat-up.

 

[07navi]

Thanks guys. I was not sure if the controller itself was the issue, or just the harness connector. Sounds like its not making good connction, causing the heat-up.

That connection is one of those things that typically goes bad on the the Expys.

 

[craig72]

Yeah, it's up at the dealer now. They're going to replace it along with some other work they're taking care of under the CPO warranty before it expires.

 

[craig72]

Got the truck back from the dealer today. They addressed the blower problem by replacing the blower resister and the blower motor itself. From the paperwork, it doesn't look like they had to replace the connector itself, but I'm going to poke my head in there today at some point just to see. Either way, they were able to duplicate the over-heat issue and verified it was no longer there after the repair.
While it was in the shop, I had them check a small oil leak I had noticed on the front of the engine while I was doing my last oil change. They said the timing chain cover gasket was leaking and they took care of that as well. Said that was a big job, and judging by the material/parts they used, it sure sounds like it. Yay for warranty work

 

[Motorcity muscle]

Sounds like you have good dealer there.

 

[craig72]

Sounds like you have good dealer there.

This was our first time using them. It's not where we purchased the truck, but is the closest dealer to our house. I really have no complaints with the work they did. Good communication, fixed all of the verifiable problems we pointed out, and seems like they thoroughly looked into other concerns. For example, my wife noticed that when the truck was switched into Auto 4WD, there seemed to be more drive train noise than we were used to (compared to our old 98, which didn't make much noise). They looked into it, but did not find anything wrong. However, the technician noted that the front differential was a little low on fluid, so he topped it off. Seems like a well run shop.

 

[mjp2]

Name-drop the dealership. If they're doing good work they deserve some recognition.

 

[craig72]

Well, a year later and we're having the same issue. What is it with this connector that keeps failing? Is the gauge too small causing it to overheat, or is it simply poor connection causing the heat-up? Anyone have a permanent fix?

 

[99WhiteC5Coupe]

Well, a year later and we're having the same issue. What is it with this connector that keeps failing? Is the gauge too small causing it to overheat, or is it simply poor connection causing the heat-up? Anyone have a permanent fix?

I am surprised the dealer did not replace the connector referenced in the link in Post #4, as it is an instruction to the dealer to replace the connector when other parts are replaced for an inoperable blower.

You may want to replace the affected connector per the TSB.

Here is an excellent video on how to replace it if you do it yourself: https://m.youtube.com/watch?v=42Ae37Zx90E

I don’t have answer to your question, but I believe it is a known poor quality / design part that Ford had known about for years, and chose to ignore trying to improve the connector.

 

[Dennis_H]

I had an older (1998) Dodge van that used to go through those type connectors. It would end up melting right at the resistor. After the second time, I got both sides of a 4 pin trailer connector with pigtales. Soldered one side to new resistor and other to exiting wire harness. Never had another issue.

 

[Motorcity muscle]

Surprised they did not swap harness at dealer. When I replaced the resistor on my '09 there was one wire that needed a new connector, it was melted.

 

[craig72]

New harness ordered. I'll get that swapped out and we'll see how it does. Thanks!

 

[craig72]

So far the new harness seems to be doing it's job. I installed it about 2 weeks ago and no complaints yet. Hopefully the newer design from Ford fixes whatever the flaw was with the old one.

 

[99WhiteC5Coupe]

So far the new harness seems to be doing it's job. I installed it about 2 weeks ago and no complaints yet. Hopefully the newer design from Ford fixes whatever the flaw was with the old one.

Are you aware that your vehicle is now subject of a Ford safety recall for the potential that the front HVAC blower motor may catch fire while the vehicle is running: https://static.nhtsa.gov/odi/rcl/2022/RCMN-22V648-9794.pdf

 

[craig72]

Are you aware that your vehicle is now subject of a Ford safety recall for the potential that the front HVAC blower motor may catch fire while the vehicle is running: https://static.nhtsa.gov/odi/rcl/2022/RCMN-22V648-9794.pdf

I was not! But I am now... thank you. I assume a letter is on the way.

 

[azsheepdog]

I have a 2012 and 2014 expedition and both have this issue of intermittent blower motor issues and the plug gets super hot. My mechanic said the blower motor is causing an over amperage causing the shut down and the super hot connector. we replaced 1 of the blower motors in the 2012 and it seemed to fix the issue. replacing the blower motor in the 2014 now and hopefully also fixing the issue. I find it odd that 2 expeditions 2 years apart are having the same issue at the same time.