It has been a long time since I've asked a question on any forum, I have searched but had no luck.
First of all. 2007 Trailblazer SS 2wd. just turned 160k. I bought it from the original owner a few months ago with ~155xxx on it. original motor/tranny etc. It was well taken care of and only mods are K&N intake, electric fan, and tune. Was told that all were done around 30k.
The fan is a Siemens fan with a controller mounted to it's shroud. It works great although its a bit loud. It is wired to the fuse box main hot, grounded to the chassis, and is controlled by the factory clutch fan plug.
The problem:In 5k miles, about once a month the fuse housing has melted 4 times. The fuse was originally a 30 amp and it melted and the first time it melted the plug for the clutch fan, the fuse did not pop but the fuse and housing melted and the wiring as well for about 3 inches each direction. I replaced it twice with 30 amp and each time changed the wiring, checked ground, made sure it's tight etc. Today is melted the housing of a 50 amp.... I'm not really sure what the deal is or what to do with it? Ideas? Ive had plenty of fast cars and dealt with electric fans plenty of times before and never seen an issue like this. Is the fan going bad? Would a relay help? Am I just an idiot?
Any help would be greatly appreciated.