Replaced blower motor and resistor, same problem

I lost one in 13 years and 532,000 km and never had a problem after I got rid of the plug.

 

I'm still trying to figure it out, the connectors don't appear burnt at all.
The one clue I'm focusing on is that after the fan and 2nd resistor were replaced about a month ago, it failed after a week [worked on high only]and the tech put dielectric grease on the resistor connector and it worked for another week.
So, maybe the connector has loose pins that are not apparent when it's plugged in?

 

The blower motor in my truck just stopped one day. I was driving, it worked great, and later the same day, suddenly it stopped working. As mentioned upthread, there was no burning or scorching evident on either the blower motor connector or the resistor connector, and I was getting voltage at the motor connector on all the fan speeds, so I knew the motor was dead. I ordered the OEM replacement from Amazon, and I figured while I was working there, might as well replace the resistor. So I ordered

Toyota Blower Motor Resistor - 87138-04052

one of those, too.

Here is the resistor I pulled out. I'm not an expert by any measure, but it looks much more rugged than what I replaced it with. The body of the resistor is porcelain; the green stuff around it is a ceramic slurry that appears to have been fired in a kiln to make it stick. Very rugged, and of course I didn't throw it away. For the sake of future searchers, I used my smallest 1/4" breaker bar with a 7/32 socket to remove the screws (I didn't have the right metric size socket, I think it is 5.5mm), which are the same size as those that hold the blower motor in my vehicle. However, the screw closest to the firewall that holds the resistor in really tried my patience... really hard to access it, and there was a few times the socket popped off the breaker bar and fell into the recess between the carpet and the firewall insulation. Anyway, let's hope the new resistor never needs replacement.





I would very much like to repair my original blower motor to keep as a spare if possible. I've not opened it yet, but if someone has a part number for the brushes, please share. The P/N for the replacement blower motor is 87103-04043.

 

Update,
I got tired of the all or nothing fan issues and took my truck to a local shop to hopefully fix this for good.
They tested all the circuits and determined that the resistor was the problem.
They found a replacement that they told me was an improvement over stock and recommended.
After replacing it, they tested everything again and found the original connector I installed (the first repair that lasted 1year) had 2 wires reversed for the new resistor (Im pretty sure I installed it correctly but maybe the new ones were different, could be my mistake,there wasn’t a diagram, I just spliced it in 1 wire at a time to match the factory )
Anyway,they installed the new connector that came with the new resistor and made sure the contacts were solid, and it’s working normally.
They have a 2 year parts and labor warranty, and charged 290, which is a lot but I’m done f,ing around !
Just wanted to pass on the information to check the new connections and not assume the wiring is the same.

 

Mine's a 2010 and I've fought the blower motor and resistor many, many, times. Others on the thread have suggested a new connector and they are right. Chances are the it's the connection and not the actually resistor or blower. Not always but often. I have found that bending the pins slightly toward the connector, polishing the connectors with steel wool, and spraying electrical cleaner solves the problem for a few months. When the connector gets burned to the point of being so warped it won't connect you need to cut them off and put on the new one. You can find those online and they are easy to install. I know its controversial but I always use dielectic grease on the connectors. (Yes, I know it isn't a conductor but actually resist electrical current). It creates an airtight seal around the actual copper to copper contact which reduces arcing and oxidation. I have also found that the connection to the blower itself can got corroded and needs the same TLC. It's a weak point with these trucks but at least it's an easy access fix.

 

Timely discussion as on my 2011, the fan just stopped working driving up to DC. Nothing works. So in terms of the resistor, where exactly is it located? I've seen the pictures out, but where do I find it?

 

Give the blower motor a whack with something metal...straight up on the bottom of the motor.

I had purchased a new blower motor due to squeaking/ticking and sometimes intermittent operation. Decided not to change until the old one finally crapped all the way out. It wouldn't spin one day when I was leaving work, so I took the 15" Crescent wrench laying on the passenger floor and smacked it pretty good (already had new one waiting at home anyways) and it started working again and has been since (8 months ago). The new motor is still sitting in my basement. Original blower motor 12.5 years old and still working! "BFH" repair.

 

Yep, I just smacked mine with my hand. I think it's one of those issues described above!

 

I believe its a resistor issue if u fan works only on high speed. If the fan works sometimes on n off n completely its a connector issue. I just purchased fan, resistor, resistor wires n found out toyota change the resistor n wiring design. The resistor n wiring is no longer 4 wires in a row. It is now a square design 2 top n 2 bottom

 

Oh joy... Did they provide a diagram for the new plug vs old?

 

Luckily the wires are the same color

 

So i found out the hard way that my connectors r bad instead of the usual resistor. Ut i started to think what caused the connector to burn out in the first place. So i am going to go ahead and replace everything. The conector, the resistor, resistor wire, and fan blower.

 

Reviving a dead thread - apologies -

Is there a how-to on this? I’m not great with electrical but I’m pretty handy so I was hoping to see if anyone had posted a tacomaworld style DIY.

thanks!

 

How to on what? Replacing the connector, resistor, diagnosing the circuit???

someone was looking for a repair connector for the blower motor the other day and I found one on Amazon for them. Here it is

$11 6" Blower Motor Connector Plug Wire Harness Pigtail Kit with Heat Shrinks Connectors Fits 2005-2016 Toyota Tacoma Replace 82998-12380 90980-10916

https://www.amazon.com/Connector-Co...37------------&vehicleName=2005+Toyota+Tacoma

 

replacing the connector.

 

Cut the old one off, strip 1/4” off the end of the wires and splice to the new connector using the supplied connectors and pliers like these:

$15 Gardner Bender GS-388 Electrical Pliers, Crimper & Cutter, Comfort Grip, Aluminum & Copper Wire, Hand Tool, 8 in. , Red

https://www.amazon.com/Gardner-Bend...31&sprefix=Electric+all+crimp,aps,239&sr=8-16
Don’t cross the wires or the motor will run backwards.
heat the connectors with a big lighter to shrink the insulation down and seal it up. If the terminals on the blower motor are burnt up too, might want a replace it or at least clean them up. A little dielectric grease on the terminals will help keep it from doing it again.

 

Reviving a dead thread.

Anyone find a good motor replacement over OEM. I think I bought the TYC and it only lasted 4 years. Died today. Ughhh.