Here's a step-by-step troubleshooting guide:
1. Safety First:
* Disconnect the battery: This is crucial to prevent further electrical damage or fire. Disconnect both negative and positive terminals.
* Ventilation: Ensure the vehicle is well-ventilated to clear out any lingering smoke.
2. Visual Inspection:
* Locate the Blower Motor: It's typically located behind the dashboard, often accessible from under the dash or through the glove box compartment. Consult a repair manual for your specific model to pinpoint its location.
* Examine the Blower Motor and Wiring: Look for any signs of burning, melting, or discoloration on the motor itself, its wiring harness, or the resistor pack (a common failure point in these vehicles). Pay close attention to any fraying wires, especially near connections.
* Check the Resistor Pack: The resistor pack controls the blower motor speeds. It's often a separate component near the blower motor. Look for any signs of damage here as well.
3. Testing (Use caution - electrical components can retain charge):
* Check the Blower Motor Resistance: With the power disconnected, use a multimeter to check the resistance of the blower motor windings. A repair manual will provide the expected resistance values. A very low or very high resistance, or an open circuit, indicates a faulty motor.
* Inspect the Wiring Harness: Carefully examine the wiring harness for any breaks, shorts, or damaged insulation. A multimeter can be used to check for continuity in the wires.
* Check for Voltage at the Motor: With the battery reconnected and the blower switch ON (at low speed initially), check for voltage at the motor's connection points using a multimeter. If you're not getting voltage at the motor, the problem lies in the wiring or control circuits before the motor. If you have voltage, and the motor still doesn't run, then the motor is suspect.
4. Further Troubleshooting:
* Check the Fuse: While the control unit is new, there might be a fuse protecting the blower motor circuit. Check your vehicle's fuse box.
* Consider the Squirrel Cage: The squirrel cage is the rotating part of the blower motor. If it's seized, it can cause excessive current draw and smoke. This requires motor disassembly to inspect.
* Consult a Wiring Diagram: A wiring diagram for your specific 1995 Ford Explorer will be invaluable in tracing the electrical circuit to the blower motor and identifying potential problem areas. These are often available online or from repair manuals.
5. Repair or Replacement:
* Blower Motor: If the blower motor is faulty, it needs replacement.
* Resistor Pack: If the resistor pack is damaged, it also needs replacement.
* Wiring Repair: Any damaged or shorted wires must be repaired or replaced.
Important Notes:
* Professional Help: If you're not comfortable working with car electrical systems, it's best to take your Explorer to a qualified mechanic. Electrical work requires safety precautions, and incorrect diagnosis can lead to further damage or injury.
* Repair Manual: A repair manual specific to your vehicle is highly recommended. It will provide diagrams, specifications, and troubleshooting steps.
The smell of smoke indicates a serious problem. Addressing this promptly and safely is essential. Do not ignore it.
