Fix that blower switch. Permanently.

The rotary blower switch for HVAC is a big problem on these trucks. I share with you my budget fix. We remove the factory blower switch and replace with DPDT toggle switch. You will cut away the old switch and fab a few simple parts to allow mounting of the toggle. This gives you two blower speed rather than four. This panel cost $695 new, but here you can fix for $20



Hope this helps.

 

To follow up, the factory switch and connector have tendency to melt over time. It appears that the weak points in the blower system are caused by resistance build up in the switches and connectors. This cheap fix will solve a lot of your problems.

 

Cheap parts but looks labor intensive. I had two issues with my blower fan: one with the blower motor; and two, an ongoing problem with the #3 fan speed setting in that I don't have increased fan speed in that setting.
I fixed the blower by rewiring the connection with new female blade connectors - I think the size is .187". As for the fan speed issue, the problem is a bad connection in one of the wires in the connector to the blower resister. Removing that burnt wire and cleaning it helps for a month or so, but it eventually goes bad again. My plan is to pull out that wire out and install it's own connector, or just wire it directly with a bypass wire. Gotta get to it before this summer.