Hi Guys - In reading all the posts about the overheating/failure of the fan control in the Velosters I wanted to check mine out before it became a problem. I suppose the easiest solution would be to buy another one to replace, but it doesn't appear to be an option, unless you want to spend a couple of hundred to buy a whole new AC assembly.
I took mine apart today to look. With only 40000 kms onboard, it was already showing some carbonization/heat discoloration on the fan contacts. I think there is too much current draw through these contacts and the grease they use as lubrication may also be impeding the current flow, leading to heat buildup and eventual melting of the plastic connector assembly as seen in some threads on this.
Sorry, I already had everything apart when I decided to snap some pictures. I will try to do a little repair tutorial here:
Too bad we can't simply buy the 1 dollar replacement fan switch
Hope this helps
I took mine apart today to look. With only 40000 kms onboard, it was already showing some carbonization/heat discoloration on the fan contacts. I think there is too much current draw through these contacts and the grease they use as lubrication may also be impeding the current flow, leading to heat buildup and eventual melting of the plastic connector assembly as seen in some threads on this.
Sorry, I already had everything apart when I decided to snap some pictures. I will try to do a little repair tutorial here:
- Remove the V shaped bezel by pulling away from the dash using a screwdriver inside the 2 slots about 90 degrees apart near the bottom of the V. This is very hard without damaging the surrounding dash. I used a pick tool and had to pull very hard, then use plastic pry tools once I had some space around the bezel. Scary. A beer or beverage of your choice nearby and keeping your kids out of earshot will greatly assist.
- Disconnect the connectors for the AC controls, fan switch, heated seats (if equipped) and whatever else
- Unscrew the AC assembly from the back of the V
- Gently pry the white back off the assembly at the tabs (below)
- Unscrew the black switch from the circuit board
- Keep in mind the orientation of the switch pieces, gently pry apart the switch
- Remove grease/carbonization with alcohol, and buff surface of contacts with a scotchbrite pad or something similar (green fuzzy square in above photo)
- Only remove grease from the metal sections - leave the grease on the white plastic nipples (middle part, above) as these work as the detent positions for each fan speed
- I work in electronics so I added a contact enhancer called Stabilant 22 to the contacts, hopefully this will assist in promoting a good contact in this high current situation. Don't use a contact grease as if it reflows due to heat it will short out to the adjacent contacts. Stabilant 22 will not run. It's not like people will have this stuff laying around the house so simply cleaning the surface as above should suffice
- Reassemble in the reverse order
Too bad we can't simply buy the 1 dollar replacement fan switch
Hope this helps