How to Rewire a Fan

Simple box and oscillating fans usually last a long time and are pretty much trouble free. The electrical cords that power them are exposed to much wear and damage, and usually wear out before the fan does. Don't trash that fan with the frayed electrical cord. Rewire it following these directions.

Instructions

Difficulty: Moderate

Things You’ll Need:

• New cord with plug attached
• Screwdrivers
• Black, white and green electrical tape
• Soldering iron and solder
• Electrical connectors
• Electrical plier/stripper combination

1. Purchase a new replacement cord of the same length and rating as the original. If the fan has a two prong plug, then buy a cord with a two prong plug attached.
2. Ensure the fan is unplugged from the electrical source.
3. Remove the grille or shroud by reversing fasteners holding it to the mechanism, usually screws.
4. Follow the electrical cord to where it terminates to the multi-speed or on-off switch and remove the old cord, marking the terminals with different colored tape, so you will remember which wire went to each terminal, see tips below.
5. Replace the old cord with the new one by soldering the wires to the terminals or attach push-on connectors to the ends of your new wire by stripping the insulation back about 3/8 inch on each of the new wires with a pair of wire strippers. Slip a push-on terminal over the bare wire and crimp in place with pliers.
6. Put the fan back together, reversing the order in which parts were removed.

Tips & Warnings

• Appliance cords have two or three wires, one being the hot wire, typically encased in black plastic coating, one the neutral wire, typically white coated and some include a ground wire that is coated in green. The hot wire will usually have ribbing along the plastic shielding or some other marking and the neutral wire will be smooth or unmarked.
• Don't replace a polarized plug (one blade wider than the other) with a non-polarized. Always replace with the same size and kind of electrical cord. Never remove the grounding pin from a three-prong plug.
• Take care not to damage the terminals and that no bare wire is touching any other piece of metal, other than the terminal it belongs on, when you are done making connections.

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