@dataway: one thing you forgot to mention was measure the temperature of various components under load. What I've found in my '66 GTO, the relay gets hot with the blower on med-hi and especially on hi. And it's an NOS relay with virtually no time on it. Other hot spots are the blower spade terminal, the spade terminals on the relay and fan speed switch. The resistor block connector stays cool enough.
I've checked the condition of all those various terminals and they all look perfect, but obviously they have too-high resistance. Next step is to replace the A/C harness with a new one to hopefully alleviate the high resistance in the terminals. Just not sure the aftermarket harnesses are of sufficiently high quality...
Another trouble spot is that ridiculously low-quality inline fuseholder behind the alternator that only A/C cars have. I replaced mine with a modern OEM GM inline fuseholder which holds an ATO fuse in a sealed housing.
|