why does my blower motor wires keep melting?

oh forgot to mention ive already replaced the motor with an aftermarket brand which did the exact same thing... anyone know what guage wire the blower motor wire uses? might just hardwire it to the battery with a fuse & cutoff switch...

and in the fuse panel there is a fuse for blower which is 10 amps...

OK here is my draw up for my circuit.. im assuming that the blower motor pulls 30 amps or less

4 awg is just to support the the maximum 100 amp fuse box as the manufacturer recommends 6-4 guage wire... other than that 10-12-14 guage wires for each connected accessory..

id rather over kill it than to have melting wires.. had hyundai over killed it we wouldn't be having this conversation...

new draw up... you think connecting a 20 amp relay to the current fan wires will allow me to use my built in fan switch at least to signal on & off?

have a link for this variable speed switch? can't seem to find one thats meant for DIYers..

reason i ask is that the fan switch is what turns the entire system on...

so if fan switch just grounds it could wire problem be caused by faulty blower switch?

either way the wire that keeps melting for some odd ball reason still gets 12v to power the motor.. if i connect that to my relay to signal my new power source to turn on... then put the fan speed switch between the relay and the blower.. this way i can leave the speed set on 1 thing and it still turns off and on via the same switch that turns the rest of the system on

Does it look like this? Is it 10g wire running to the clip? I'm trying to make a bypass for the clip.

so when it melts the plugs, where are you finding replacements? i've got the same problem and need a new plug. i think i've found the factory replacement, but i'm not sure it's the right one.

I'm having the same problem. Has anyone found where to buy a new clip?

My car did the same thing I have a 2007 Hyundai Accent SE. I replace the end of the wire and plugged it back in but a spark occurred during the process now my car will not start

I just tried something a couple days ago. I was at a parts yard called u-pull u-save and i looked at 10 2006-2011 hyundai accents. To no avail, i discovered all of them were burnt up ir heading there with browning plastic. So i gave up. On my way out i seen a 2008 kia optima so with one last glint of hope i pulled the heater motor out and it was clean and new looking so i cut the wire with plug and took it to a 2007 hyundai accent and it bolted up, lined up and the wire was not long enough as it plugged in an inch away from original location but the plug was the same. So i had already cut and spliced my melted plug in my 06 accent now i just made the wire longer by adding some (not stretching it lol). And this fan works 3x better. It doesnt heat up, ive run it for several hours on solid 12v black and red wire tied together. Now i have the speed selector in the heater control as a used one, it twists and popps out the back after you press down on the security release button then it will spin and come out. That part is also what melts as the factory fans wear out. Everything works well and is going strong. You just have to do a quality job of wiring up the new/used parts. But it is only day 3. Does the kia optima motor fail at some point? Im not sure but after 3 fan and selector replacements im hoping this does the job

Working on a 2008 Hyundai Accent 2-door hatchback. Replaced the resistor, blower motor, cabin filter too. I can't find a connector for the new blower motor.The two prong connector finally melted and cracked after 12 years. Is there a part number for it or should I go to a salvage yard? Ebay and Hyundai part dealers don't seem to have them in their parts department either.

My replacement blower came with a cable, so I cut off the burnt connector and crimped on two yellow fast-on lugs, but I think may have reversed the polarity. When I turned on the fan the plastic blower assembly cracked. I assume that the fan spins faster in reverse as the blades have less resistance spinning in reverse. Could someone confirm that the fan supposed to turn counter clockwise? (looking at the blower assembly) FYI: I think the connector part number is DJ7021-6.3-21