Troubleshooting AC + Heater
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Senior User
Joined: Apr 2016
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From: Austin, TX area
Ok, I did the tests.
I got nothing on the tester for the +/Orange nor the -/Brown per your outline above.
I tried both the Accessory position and one forward from Off on the ignition switch. All of that was done with the blower set on High and the AC/Heater set to Vent. I think the temp was set to cold.
I believe I just need to insert the probe far enough to touch metal in the plug on the proper side, correct?
I got nothing on the tester for the +/Orange nor the -/Brown per your outline above.
I tried both the Accessory position and one forward from Off on the ignition switch. All of that was done with the blower set on High and the AC/Heater set to Vent. I think the temp was set to cold.
I believe I just need to insert the probe far enough to touch metal in the plug on the proper side, correct?
Fleet Owner
Joined: Aug 2005
Posts: 23,668
Likes: 301
From: Easton,Ks
Make sure your test light is making contact with these circuits.
Thread Starter
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Senior User
Joined: Apr 2016
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From: Austin, TX area
Should I be exposing wire for these tests or is using the probe into the plug sufficient?
I attached my test light alligator clip to the POS (+) post and inserted the probe to the power plug on the side with the Orange wire / black stripe, making sure I was touching metal of the interior prongs. Nada. Turned back off and took the tester off.
I attached the NEG (-) post to the clip next, and inserted the probe into the power plug with the Brown Wire / Orange Stripe. Moved ignition to ON. Still nothing.
Wouldn't this indicate the power plug itself is toast? Or is there something else I can check?
I attached my test light alligator clip to the POS (+) post and inserted the probe to the power plug on the side with the Orange wire / black stripe, making sure I was touching metal of the interior prongs. Nada. Turned back off and took the tester off.
I attached the NEG (-) post to the clip next, and inserted the probe into the power plug with the Brown Wire / Orange Stripe. Moved ignition to ON. Still nothing.
Wouldn't this indicate the power plug itself is toast? Or is there something else I can check?
Thread Starter
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Senior User
Joined: Apr 2016
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From: Austin, TX area
I removed the wire loom from the wires powering the heater blower motor. They look perfectly fine, except potentially right near the plug connector itself.
Heater Blower Motor power wiring
I have seen some wire tone devices that can diagnose breaks in a wire. Harbor Freight has one for $25 and I've got some store credit with them. But I don't know where the other end of the orange/black stripe or brown wire ends. They disappear through the wire cluster into the dash.
I can also confirm now with the blower motor removed that the vacuum line is NOT operating the cold/hot door inside. This was done with the battery disconnected and the truck off. If I move the lever arm on the vacuum unit manually it WILL open and close the door - it is not stuck.
[***************]Save[/COLOR]
Heater Blower Motor power wiring
I have seen some wire tone devices that can diagnose breaks in a wire. Harbor Freight has one for $25 and I've got some store credit with them. But I don't know where the other end of the orange/black stripe or brown wire ends. They disappear through the wire cluster into the dash.
I can also confirm now with the blower motor removed that the vacuum line is NOT operating the cold/hot door inside. This was done with the battery disconnected and the truck off. If I move the lever arm on the vacuum unit manually it WILL open and close the door - it is not stuck.
Thread Starter
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Senior User
Joined: Apr 2016
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From: Austin, TX area
@Lead Head
OK. I have the center dash opened + the radio removed as well.
HVAC controls
You want me to check power to this unit?
OK. I have the center dash opened + the radio removed as well.
HVAC controls
You want me to check power to this unit?
Thread Starter
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Senior User
Joined: Apr 2016
Posts: 291
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From: Austin, TX area
Here is another shot of the internals behind
[url=https://www.flickr.com/photos/93660723@N05/]HVAC controls close up[/url
[url=https://www.flickr.com/photos/93660723@N05/]HVAC controls close up[/url
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@Lead Head
OK. I have the center dash opened + the radio removed as well.
HVAC controls
You want me to check power to this unit?
OK. I have the center dash opened + the radio removed as well.
HVAC controls
You want me to check power to this unit?
Fleet Owner
Joined: Aug 2005
Posts: 23,668
Likes: 301
From: Easton,Ks
Ground G201:
/
Thread Starter
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Senior User
Joined: Apr 2016
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From: Austin, TX area
I think I found the problem.
heater switch power
So, I will need to replace the plug. The unit itself also looks pretty scorched from the outside. Which pigtail do I use for this?
Also, I don't see how I remove the switch unit. It's still attached on the right (and zip tied on) in addition to something on the bottom holding it in. And that's before I disconnect the wire actuator.
heater switch power receptacle
I am assuming with that much damage to the plug, the unit is likely toast as well.
Here's a view of the rest of the unit on the middle & right.
heater switch assembly[***************]Save[/COLOR]
heater switch power
So, I will need to replace the plug. The unit itself also looks pretty scorched from the outside. Which pigtail do I use for this?
Also, I don't see how I remove the switch unit. It's still attached on the right (and zip tied on) in addition to something on the bottom holding it in. And that's before I disconnect the wire actuator.
heater switch power receptacle
I am assuming with that much damage to the plug, the unit is likely toast as well.
Here's a view of the rest of the unit on the middle & right.
heater switch assembly
Last edited by TexanAmmo; Sep 19, 2016 at 07:48 PM. Reason: Made the photo a bit smaller, added more detail
Thread Starter
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Senior User
Joined: Apr 2016
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From: Austin, TX area
After digging in there further, I found...
- Red 4-prong power plug on the back right of the unit (I think that is power out?) now disconnected
- Yellow 6-prong hexagonal-ish pass-through connector now disconnected
- Grey 2-wire connector (perhaps a fuse?) - still connected
- The actuator cable (how do I remove that?)
What do I do now?
- Red 4-prong power plug on the back right of the unit (I think that is power out?) now disconnected
- Yellow 6-prong hexagonal-ish pass-through connector now disconnected
- Grey 2-wire connector (perhaps a fuse?) - still connected
- The actuator cable (how do I remove that?)
What do I do now?
Thread Starter
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Senior User
Joined: Apr 2016
Posts: 291
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From: Austin, TX area
OK, I know how to get the plug out just by cutting wires. I can try out my soldering skills. It's been a while but I soldered the charge controller for my solar panel so I can get this. If I can't find a junkyard truck with it, what is that part called so I can order a replacement?
But how do I properly remove the actuator wire? I can just pull the end out of the actuator arm, but what about the part just behind that with the blue plastic piece? Is that just glued to the white plastic?
But how do I properly remove the actuator wire? I can just pull the end out of the actuator arm, but what about the part just behind that with the blue plastic piece? Is that just glued to the white plastic?