I am troubleshooting what may be a bad blower motor on a 2011 Ford Fusion SEL 6cyl and cannot seem to find any useful specifications for the part (AE5Z-19805-D). Here is the breakdown:

The blower motor stopped working (the A/C also needed to be charged and I had it on auto, perhaps related?)

I pulled the blower motor and blower motor resistor and found that the blower motor resistor plug was melted to the resistor.

I ran the Ford service manual "Pinpoint Test S: The Blower Motor is Inoperative DATC" and confirmed that the blower motor is receiving >10v from the blower motor resistor.

This leads me to believe the motor is bad and drawing too much power. I have a new motor, resistor, and resistor plug on the way but I wanted to bench test the motor to confirm that's the problem (rather than run some shotgun maintenance and blow another resistor if there is a separate problem). I don't know what kind of power draw is considered "within specs" without knowing what those specs are. Does anyone know how I can find these?

 

Welcome to the site..

With DATC the system would have a blower speed controller, EMTC would have a resistor.

The blower speeds are done varying ground resistance or feedback. Generating heat. The blower motor when tested (if run with standard voltage) and no ground reduction would just run at max speed. If the motor runs at max and has no circuit protection issues while bench tested on extended running, the connector shouldn't fail before the protection did. Although, it takes the full potential of the loads draw..
The motor being the load and it's connection to either a resistor of controller,, the blower motor connector itself could take the collective fail if any additional resistance or connection issues over time subjected to heat at that point.

Unless the DATC had issues with temp control, vent location fail concerns, DTC's, being the fail was noticed in Auto, shouldn't be related. If the motor was cause, the motor itself should have been the heat source, most likely failing the blower controller, relay, and/or the circuit protection... If this is a EMTC system, resistor ohm value checks are available...

 

Thanks, Hayapower, for the reply. My Fusion has a DATC system so, you're right, the part I am referring to is the blower motor speed control. I have a power supply that can source up to 5 amps and I am able to run the motor at almost a constant 12 volts. The power being drawn by the blower is greater than my power source and so there is a slight voltage drop. I was hoping to find the power specifications (perhaps some sort of voltage vs current chart or power vs speed chart) that could help determine whether the motor is running correctly or not. If the motor is fine then I suspect the problem could only have occurred via a short in the speed controller or due to a poor connection between the speed controller and the harness going into it. At this point, I will likely just replace all the parts but I still worry that this problem could be external to these three parts and cause the same problem (and cost me an extra $100+ in parts).

 

Swapped out the connector, blower motor controller, and blower motor. Everything is working find now. While the off-brand blower motor I got as a replacement is a little more power hungry (based off of bench tests) I don't want to risk the original blower motor being the problem and burning everything out again. Turns out my cabin air filter was filthy (perhaps that was the culprit, or at the very least exacerbated the problem). Now I need to figure out why my compressor clutch is kicking in and out randomly. I'll post that elsewhere. Thanks for your input!

 

Thanks for the update..