Back of ignition switch gets hot

[rar7775]

I uploaded a few picturs on snapbucket. Here are the links:

http://pbckt.com/pr.NGNZ4T

http://pbckt.com/pr.NGNbZD

I just disconnected the electric water pump and electric fan from the ballast resistor and that didn't change how many volts are going to the back of the ignition switch. With them disconnected it read about 19 volts which is the same as the volts at the coil (and about the same with them connected to the ballast resistor) Way too high! I'm out of ideas to try... :disappoin Any suggestions? Anything I've missed? Thanks again!

Richie

[Zed Head]

I would get a better voltmeter, or borrow one. I don't think that these alternators will even put out 22 volts, especially at low RPM. I think that your measurements are incorrect.

The measurements from your Town Car confirm the bad readings, and secondarily, show that your Z car charging system is probably fine.

It's not the voltage causing the heat, it's the amps that you're pulling through the switch with the fan and pump. You should install some relays to run those motors.

[rar7775]

I'm willing to try anything for sure, but when I disconnected the electric fan and electric water pump (for a brief time ) the wires still got very hot and showed the same on the volt meter albeit possibly bad it at least shows consistency.

How would I run relays to those electric motors?

Richie