Blower fan resistor?

1996 Grand Am SE 2.4 with air conditioning

Blower fan doesn't work on highest setting. All other settings work. (Opposite of the normal resistor problem!)

I've already replace the blower fan.

Still think it's the resistor?

you are right, it is.

On setting 5 it usualy bypasses the resistor and uses direct current(12vlts) to the fan.

Did you check the blower motor fuse ?
And I'd check that the plug in to the resistor is fully connected.

Check out what Xero said to. When mine went out I found the connector on the resistor and from the ac/heat control head was melted. So that could be a possibility.

my bad it is not resistor, xi is right I just checked the diagram you have 4 speed settings and the 4th speed bypasses resistor using blower motor relay and blower motor 30 A fuse. So check both Blower motor relay right rear of engine compartment and (that is going to be your left side when facing the windshield, you will see all the relays and look for the one that has this wires (black, brown, orange, dark blue and purple) check if you have battery (ignition key off) voltage at the orange wire when you disconnect the relay if yes, replace the relay, if not chekc the HVAC. BLO. MOT. fuse 30A

oops! I forgot this model only went to 4 on the blower. :lol:

S. happens. I did even worse by telling the guy to remove the plastic covers around the steering wheel to find the security connector. Totally forgot that the ignition cylinder on 99+ is on the dashboard. :grinno:

Well, I changed the resistor because I'd already ordered one. No worries...it didn't cost much. And, you all were right...it didn't fix the problem.

So, I took 3100's advice and checked the fuses and relay. I checked the fuses first, because that was easy to do. Both fan fuses were ok. (Yeah, I know I only needed to check the one outside, but I'm just being fussy.)

Next, I found the correct relay and removed it. As soon as I unplugged it, I knew I had a problem. The plug hole corresponding to the orange wire is melted. The relay LOOKS fine, but I don't know whether or not it actually works.

My new problem is figuring out how to fix the plug. Can I get a new one? Can I fix the old one?

Any ideas? It's really melty. They plastic is ok, but the metal part is pretty much gone.

you can find new one maybe in auto zones, but if not then just memorise where each of the wires connects and just buy 5 of those separate (FEMALE) connectors that are correct size and then you can plug them in separate one by one. (they come in different colors: red, light blue, yellow etc.) Home Depo has them.

also melted wire tells me that there could be short. Did you check voltage at orange wire, since there are two fuses, one for bypess one for resistor? Maybe fuses are OK, but there could be then open in orange wire somewhere. Also for the bypess make sure it is 30A just in the case that someone did not install bigger fuse. Then disconnect that fuse (30A) use dovom, set it to continuity test, put one lead to orange wire and the other test lead to any ground just to test for short to ground. If you hear a beep it is shorted somewhere. Or relay's is rusted and creating more resistance and pulling more amps than necessary thus heating up the wire. You will still have to replace relay.

That is what happened to the connector on my GP. It was all melted, the black and orange were melted also. It sounds like the blower motor may be draw too much current. Is or was the blower motor squealing, if it was that may be the reason why there is melted wires.

Since you already replaced the blower motor it is possible that the connector got melted during the old blower motor. If your 4th speed did not work since then then I wouldn't worry much just replace connector, but if the 4th speed quit working after new motor was installed then I would worry about what doctor and I are saying.

I replaced the relay today and the blower works on HIGH.

I didn't do any diagnostic testing.

I'm a little concerned that HIGH might have stopped working AFTER we replaced the blower motor. If that's the case, I'm hoping it was just because the relay was about to go anyway. We'll see how the new relay and new blower get along. Hopefully, everything is ok.

Thanks to everyone for your help. I don't think I would have ever thought about that relay if someone hadn't mentioned it.

Well, that lasted for about two hours.

My son informed me that the blower isn't working on high again.

Guess this isn't going to be so simple after all.

do the tests that I suggested above, you could have shorted orange wire.

I did the test that 3100 recommended, and there's no short in the orange wire. No continuity with the fuse pulled. Just for fun, my son kept plugging and unplugging the fuse, making the tester buzz...so, we're sure there's no short circuit. :-)

I'm wondering if maybe I just got a bad relay from AutoZone that conked out soon after I plugged it in. I think tomorrow night, I'll see if I can exchange it and see if a new one lasts longer.

When I replaced the blower fan, I bought an aftermarket fan from RockAuto.com. It was listed for the 1996 Grand Am SE, though. Hopefully, the blower fan isn't somehow causing the relay to blow on the highest setting. It works fine through the resistor.

That's my story so far.

Any new ideas?

go on junk yard and just cut off another rely connector, since that connector inside is melted it is probably poor connection creating a lot of resistance and heating up even more or just buy 5 separate female connectors that would click in with the male terminals of the relay. Connect them with the corresponding terminals and you should be fine. Most likely the old motor was shorted and destroyed the terminal for the orange wire and when you push in with the relay it probably does not make good connection and poor connection = high resistance=more heat

I would agree with the relay connector being part of the problem.
Seen it before! Ive also seen the blower plugs melt and short the blower motor from a bad relay connectors shorting.

If you do use female terminals make sure they are coverd with either rubber(silicone) covers or plastic so they cant short agian. :2cents:

Hufhouse, it is OK. to admit that it was the connector :)

did you ever find out what it was?

Actually, I've been so busy with work I haven't even gotten to tear into it again.

I've been putting it off...avoiding the frustration.

is there any way to put a meter on the resistor to test it

after looking at another thread that showed an old vs new resistor, the old one was visually bad the resistor i pulled out has been replaced once before and is the new design and does not shows any bad areas on the grid is this a sign that the resistor may be good, in the morning i will check fuses and relays at the present time no fan speeds work

ok took the blower motor to the shop and it is dead, they hooked power directly to it and nothing, bought new motor hooked everything up nothing, unplugged the blower motor and no power at the plug the one part i haven't checked is the switch how often do they go bad and is there any other thing i should check oh yeah it is a 2001