Possible blower fan issue?

Hey all, gonna start trying to track down an issue I've been having with my blower speeds. I've already been through a couple of resistor modules but now it's presenting a different issue. When a resistor goes bad, i get the classic only-works-on-max problem.

But for the last couple months, it seems that setting 1 and 2 are both almost identical and produce just a tiny trickle of airflow, while 3 and 4 work normally as far as I can tell. This is annoying because I like running on setting 2 85% of the time, as it's nice and quiet but adequate, when the higher settings are overkill and noisy(not abnormally noisy, just louder airflow than I prefer unless needed)

Should I be looking at the resistor again first, or could it be a problem with the switch assy?

Yes, I've already changed the filter lol, just haven't broken out the multimeter yet and started testing

thanks!

 

Sounds like a bad blower motor..

 

Damn. Was hoping it wasn't that, I just replaced it a couple years ago. Wouldn't that affect all speeds though? Like I said, 3 and 4 work normally, I just don't usually like setting it that high after initial warmup/cooldown

 

You mentioned it made noise at high speeds….is it an aftermarket blower motor?

 

Oh, sorry, i didnt mean abnormal noises. It's just louder than I prefer from the airflow itself at high speed. Same as the original motor, I honestly don't recall if I replaced it with aftermarket but I may have.

 

I'm on my third wiring kit and sensor. I think maybe it's time for a blower. I think I remember somewhere you can use a 3rd gen for more cfms? Or something. Anyone know about that??

 

You want a load that draws similar current as a blower fan. Make a test light using a headlight bulb and a couple of blade connectors, and connect it to the blower wire harness. Check for 4 distinct brightness levels when you turn the fan switch. You can also connect the voltmeter in parallel with the light to check the voltage. If you see 4 distinct brightness / voltage levels, replace the blower. If you don't see 4 distinct brightness / voltage levels, either the resistor or the switch panel is bad.

Also check for mouse nest above the cowl intake. Remove the cabin filter and look up with a mirror and flashlight.

 

If you have been through a few resistor packs, it's then likely a faulty blower motor that is drawing too much amps burning the resistor packs. I would also check the fan speed switch wiring in the back to confirm there's no melted or corroded wiring.

 

From my experience, if one of the fan speeds is not working, you may have a corroded connector at the resistor connection. If fan only works on high, you may have a corroded connector at the blower.

1 - The resistor connector will have four wires. If any look discolored, it will have a loose connection. If careful, you can remove the wires individually to clean with wire brush or sandpaper. Add dielectric grease when reconnecting.

2 - The blower motor is a two-plug connector. As above, check for discoloration. Mine got so hot the connector was partially melted. Using a pick, I was able to break through the plastic to remove the connector. I cut off the male plug and wired in blade connectors, .110 I believe, with 10 gauge wiring. It’s been about six years and oem blower still works. Note: you may have to remove the blower to work on it.

One of my blower speeds recently started going out. I’m have to clean up the resistor connector again.