Fan speed switch not working.

So I've been scrolling for a little looking for the answer (look with your eyes and not your mouth, right?) but haven't been successful. I was having the issue of the switch only working on high two weeks ago, so I swapped out the resistor and ram bam thank you mam I was back in business. Today, two weeks later, the fan is back to only working on high. I assume this is a symptom of a larger issue, but I'm not savy enough to figure that junk out on my own.

Any ideas? Thank you!

 

You have to replace the resistor and the resistor wire connector at the same time. Otherwise, it's like treating 1 kid for lice in the 3rd grade classroom.

 

So none of this made any sense with all the numbers and colors and letters. I went to Toyota today and worked it out with them. This is the proper way to hook it up. I agree that it does not make sense that you would have a larger gauge wire hooked to a smaller gauge wire. However, Toyota made it this way. Hooked mine up this way and it works like a champ. I attached the diagrams that the Shop foreman printed out for me. Hope this helps if anyone is still trying to figure it out.

Old Harness -> -> New Harness
White/Blue Stripe -> (Hi) -> Solid White
White/Black Stripe -> (Lo) -> White/ Black Stripe
Green/Yellow Stripe -> (M1) -> Solid Green
Blue/Black Stripe -> (M2) -> Solid Blue

 

Finally, somebody posted the correct wiring with documentation to back it up. So, you just match the white/black to white/black and then from there, you just ignore the stripe colors and match color to color.

Good job Choads!

 

and here I was just lining up the wires from left to with the clip oriented towards me... There's just no help for some people!

 

I'm not sure exactly what you're trying to say, but those wire colors mentioned by Choads are for using the 3rd gen style resistor that have the 4 wires arranged in a square and not in a row like the 2nd gen connector.

 

well out of my league. Perks of being a lowly 2nd genner

 

I still think you missed the point. Apparently Toyota is selling the 3rd gen type resistor and connector for use in the 2nd gen Tacos and claiming it is more robust. A few pages back, a TW member posted this pic of the different types of connectors, but no concrete, documented orientation on which wires connect to what. Choads is the 1st to absolutely, positively show how it should be connected.

If you bought the 2nd gen style connector with the terminals all in a row, you just match up the colors.

 

Aah I see what you're saying. Thats kind of a cluster.

 

TLDR Warning:

I had the symptom of the fan only working on high and decided to do the 3rd gen resistor upgrade, I purchased the following parts:

82141-04Q80 "Harness Service Wiring Repair Kit"
87138-04070 "Resistor"

The resistor has a date code 2019.0116


The plug pinout is:


Here is a graphic representation, black is the resistor and gray is the pin

I started with this configuration and while the fan functions it doesnt appear to be functioning correctly, I have no noticable speed difference between low and medium. After digging in more I am questioning the notes in your PDF for the new wiring: *10 and *11 which show what appears to be different pinouts for the plug depending on whether it was made before or after Sep 2018. Per the following info I believe the pinout in the harness I have is incorrect.

I tested my old resistor and per the FSM test it appears to be within spec, pointing to the wiring being the problem. I then tested the new resistor, I haven't seen the same FSM printout for the 3rd gen resister so I am trying to determine which pin in the resistor is which circuit, the values are:



From that data I am assuming that common is either pin C or pin A:





Based on the deltas in values for all the measurements I am going to assume that common is A.

Back to the plug pinout the plug I received doesnt correlate to either the *10 or *11 wiring diagram. I have the following:



If common is A it would get wired as follows:

This would be the case if:
Common is C
You have a resistor dated after 09/2018
You have a wiring harness with the same pinout as what I received.



It would get wired as follows


Does anybody have the FSM page for the 3rd gen tacoma that shows "Blower Resistor Inspection" and confirms which pin is common??

Sorry for the extremely long post, I was also trying to get this straight in my own head...

 

I am convinced that for the majority of fan issues, it's not the resistor that is faulty but the wiring connectors that dont have a solid connection. Whether at the resistor connector or at the fan. I have faulty connectors at both locations. I fixed the fan connector but speed #3 still does not function; it is same speed as #2. This does not bother me; so, I've learned to live with it.

 

I just tested both configurations: Common is C and Common is A and both work, I get varying speeds of what seems appropriate speeds for each setting of the dial.

I am using butt connectors until I get this sorted out, the white stuff is unshrunk heat shrink

Before - matching colors per the Toyota recomendation that @Choads provided.


Assuming common is C:


Assuming Common is A:


I mentioned in my previous post that I believe common is A, I believe this is correct and that the wiring provided from Toyota is correct assuming the note *11, BUT, I think that the plug I received is pinned out incorrectly.

A Snip of the diagram provided courtesy of @Choads:


You can see that the pinout is the following:


I believe that note *11 is correct with the assumption that common is A.

But

The plug I received is pinned as follows:
1 White/black
2 White
3 Green
4 Blue

Instead of what is shown in the diagram:
1 Blue
2 Green
3 White
4 White/black

In order to wire the new to old as Toyota provided, the plug has to be re-pinned.

 

Purchased new Blower/motor assembly via ToyotaPartsDeal. Decided on OEM at $130 shipped. Wanted the peace of mind of air flow and noise per OEM spec. Install was easy thanks to YouTube video. All works good now. Replaced the resistor and wiring harness a few months ago (different thread) to fix the "only works on HIGH" fan speed setting. For only postage, the old one is offered on the Buy/Sell if anyone wants to rebuild it.

 

Nor the motor, not the switch, not the resistor.
Its the wiring harness.
My GF has been kicking the harness with her toes. (Nervous passenger)
Right near the resistor.
Wiggle the wires and it works or hit a big bump.
Unwrap the harness and find the broken wire.
My + wire was broken in the harness.
One butt splice and some foam rubber to protect wires from kicks.

 

First time poster looking for help:

2006 Prerunner 180,000 miles

My original blower resistor started to bite the dusk last year, I replaced it recently but LOW and became medium low power (not low). I checked out the connector and it seemed burnt so I replaced that, fixed the previous problem but now M2 (medium high) is low. So now it's:
Off - off
Low - low
M1 - medium low
M2 - low
High - high

any ideas? Wiring seems fine, but who knows without inspecting it all. Could it be the blower or the control dial or even a bad new resistor? I confirmed the new connector wiring is identical to stock but maybe I need to swap some wires in the connector for the new resistor to work right?

thanks!

 

So what is the consensus for wiring Old (flat type) to New (square) color code?

 

You may want to look into replacing the blower itself if it continues to stop working. I tried the resistor on mine and got nothing. Try putting the switch on one of the slower fan speeds and try giving the metal bottom of the blower housing a soft but firm tap (I used to end of my Maglite) to see if it starts spinning. Mine would start spinning after a tap. The worn bearings may be keeping the motor from spinning on the lower speeds.

 

What ^ said. I had the same issue, tapped hard with my fingers on the motor/blower, and now works. Thing's noisy, but my truck's old, don't care. Most things work.

 

To simplify my overly confusing posts:

If the plug you buy has the following pinout




It would get wired as follows

 

If anyone repeats the cut, strip n crimp, stagger the crimp "tubes".