Procedure for Replacing the Power Supply Fan on the PowerPC 6500 or 6400
by Lance

If the fan starts to head south on your 6500 the following procedure should
get you going again.

1) Purchase a new fan from RadioShack.com. This fan is an almost exact
replacement for the original fan. The p/n is 900-2513 and the price is
$13.00. This fan draws about 5% higher current but it also puts out slightly
more air. The noise level is a bit lower but not markedly so. It is an EXACT
fit mechanically and works great. You will also need two inches of 1/8"
shrink tubing and a small tie wrap.

2) Disassemble the 6500 and remove the power supply per the excellent
instructions elsewhere on this web site.

3) When you have the power supply out remove the four screws that hold the
case together.

4) Carefully separate the two halves of the case. Work slowly so as to not
damage any of the wiring that exits through the upper half of the case.

5) Using a small screw driver, gently release the lock on the fan connector
(on the PC board) and disconnect the fan.

6) Prior to removing the fan from the top case half, mark the underside of
this portion of the case with a pencil mark so as to indicate where the fan
wires exit the fan. This will help with correct reinstallation.

7) DO NOT try to remove the fan wires from the small white connector. This
will invariably result in damage to the connector. These types of connectors
are crimped and are not designed for reassembly.

8) Cut the cable tie that holds the plastic sleeving that covers the fan
wires.

9) Carefully snake the wires and the connector through the sleeving until
the sleeving is removed.

10) Put the two fans side by side and orient them identically with the side
with the wires facing you. Carefully route the new fan wires exactly the
same as the old fan wires.

11) Cut the connector and original fan wires approximately two inches from
the connector edge.

12) Cut the new fan wires so as to make the new fan wires and the old
connector plus two inches of old fan wire the same as the original fan wire
length.

13) Remove about a 1/4" of insulation from all four wire ends. Try not to
use too much pressure on the wire strippers so as to cut or damage the
stranded wires.

14) Slide a 1 inch length of 1/8" shrink tubing over each of the new fan
wires and move the tubing up against the body of the fan.

15) Carefully twist the wires together, make sure that RED IS CONNECTED TO
RED and that BLUE IS CONNECTED TO BLUE OR BLACK. If you reverse these wires
the fan will operate in the opposite direction. This will ultimately kill
your power supply and possibly your logic board from overheating.

16) Now solder these splices with a low temperature soldering iron and rosin
core solder. If you are not sure of your soldering skills then find a friend
who can do it for you.

17) Slide the shrink tubing to cover the splices completely.

18) Using a heat gun or match carefully shrink the tubing over each wire. DO
NOT OVERHEAT SO THE WIRE INSULATION WILL MELT. A correctly shrunk wire will
fit tightly over each splice.

19) Snake the new fan wire assembly and connector through the old piece of
sleeving. Make sure that the sleeving is oriented as before.

20) Secure the sleeving to the fan wires using a tie wrap as in the original
fan assembly.

21) Install the new fan and original grill assembly to the power supply case
half. Make sure that you orient the corner of the fan with the fan wires to
the pencil mark in step (6).

22) Carefully reattach the fan connector to its mate on the power supply
board.

23) Put the two power supply case halves together making sure that no wires
are pinched and that the power supply case tabs are aligned with their mates
on the other half.

24) Reinstall the four power supply case screws.

25) Reinstall the power supply and 6500 case per the instructions in (2)
above.

26) When you turn the 6500 for the first time you should hear the fan start
up and the computer should boot up  normally. If it does not or if you smell
anything burning turn it off immediately.

27) As one last check, put your hand near the air exit holes on the back of
the 6500. You should feel air blowing against your hand. If it feels like
air is being sucked into the computer through these holes (you can check
this with a piece of paper) you HAVE REVERSED THE FAN WIRES. Immediately
shut the computer down and repeat the above procedure correcting the fan
wire splicing mistake.