I checked the CSM but can find the fuse amp for the inline fuse on the black/orange high blower power supply. I think it's 25amp is that correct?

 

Ok I see it's a 30amp fuse but I just replaced the 25amp fuse and it actually melted the glue bonding the glass to the metal end prices ... Any ideas why it's getting so hot?

 

Resistance from dirty or corroded terminals inside the fuse holder can cause overheating. Once that starts, it's self-perpetuating also.

 

At the expense of original appearance, replace it with a high-amperage inline fuse holder properly crimped, soldered and shrink-wrapped into the power wire. Your choice of glass tube or blade type fuse and you can find these with either black, red or orange wire. You can hide it along the firewall if appearance is a concern. All of mine have been repaired this way and never lost points in OCA judging.

My experience with those things is that once they melt they're impossible to deal with.

Sometimes a blower motor will have an oil port for the bearings. If it does, a couple drops of lightweight (10w) household oil will help.

 

The blower motor could be slowly failing and drawing too many amps.

 

Unless originality is important to you, just cut out the glass fuse holder and install one of these.

Blue Sea Systems Waterproof in-Line ATO/ATC Fuse Holder
Once that is done, before trying it out find a repair shop with a clamp on amp meter. Clamp the test probe around the power cable, turn on the blower to its highest speed. Hopefully the blower motor isn’t drawing anywhere near 30 amps (it might get close during startup). As someone mentioned, if the motor is tired it can draw an excessive amount of current. The fuse will get hot, the housing will melt, that drives up the resistance, resulting in even more current draw. It’s all downhill from there.

 

Man you guys are gracious with your information. I am going to try to clean and use the original as the car is original with 46k miles, but if it continues to blow I'll put a more modern inline fuse in...again thanks for the information!!!