AC / fan only works on higher settings

[threegoofs]

Trouble. My AC in my 95 Windstar works fine as long as the fan is set to setting 3 or above. The low fan settings dont work at all.

I assume this is a short somewhere - how do I find it? Do I need to take the front dashboard panel off? How do I do that?

help!

[dougand3]

I'd think blower motor switch has corroded contacts on speeds 1 - 2. If you can get to them, may be able clean them with fine sandpaper or electronic parts cleaner. Getting this switch out to do that requires removing multiple panels. The Haynes for your year should list the steps.

[DRW1000]

Originally Posted by threegoofs

Trouble. My AC in my 95 Windstar works fine as long as the fan is set to setting 3 or above. The low fan settings dont work at all.

I assume this is a short somewhere - how do I find it? Do I need to take the front dashboard panel off? How do I do that?

help!

I assume that the blower only works at 3 or above regardless of whether the AC is on or not. In other words not AC related.

I would look at the resistors. The Blower motor itself has one speed. The way the it operates at lower speeds is through a series of resistors. At high there is no added resistor, at 4 there is one, 3 there is 2.... It sounds like when you go lower than 3 you introduce a part of the resistor circuit that is faulty and has an open (discontinuity). The resistor pack is replaceable as a unit.

[threegoofs]

Originally Posted by DRW1000

I assume that the blower only works at 3 or above regardless of whether the AC is on or not. In other words not AC related.

I would look at the resistors. The Blower motor itself has one speed. The way the it operates at lower speeds is through a series of resistors. At high there is no added resistor, at 4 there is one, 3 there is 2.... It sounds like when you go lower than 3 you introduce a part of the resistor circuit that is faulty and has an open (discontinuity). The resistor pack is replaceable as a unit.

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Yep. You're right. It isnt AC related. And now when I get to 3, it doesnt work- it only works on 4 and 5.

I have a feeling this is going to be too tough to fix on my own... looks like a mechanic bill is in my future...

[DRW1000]

I can't speak about your abilities but if you need to replace the blower resistors then a Haynes manual and some basic sockets and wrenches should get you there. I will check the procedure and let you know what is involved. It may all depend on how much disassembly is required to get to the part in question.

[kurtr]

This was a very easy fix on my '98. If I remember correctly, you access it through the removed glove box cavity. (If not, it was even easier... the area above the passenger's feet.) Look for a plate about 1.5" x 3" with a wire connector coming out of it that has two screws/bolts. It is part of the van's duct work. Very easy fix.

[threegoofs]

Originally Posted by kurtr

This was a very easy fix on my '98. If I remember correctly, you access it through the removed glove box cavity. (If not, it was even easier... the area above the passenger's feet.) Look for a plate about 1.5" x 3" with a wire connector coming out of it that has two screws/bolts. It is part of the van's duct work. Very easy fix.

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Kurt-

Thanks for the info - I think I will tackle this one on my own. Now I just have to hit a library/bookstore to find a manual on where it will be....

I did see what the part (resistor pack) looks like from a picture online. that will help.

[threegoofs]

DRW and Kurt -


Thank you a thousand times.... I found the resistor pack right under the glovebox, got it out easily, and called the Ford dealer and got the replacement part for $20. The old resistors were very corroded and the connections were broken.

I think I replaced the whole thing in about a half hour, and most of that was figuring out how to unclip the darn electic connector.

It works, too.

I bet I saved myself $100++

[DRW1000]

Glad to have helped. Thanks for posting your response too. (It makes for a complete reference in the future).

I hope you continue to visit this site. You are now the resident resistor pack expert.

Congratulations on attempting the repair yourself. Not only did you save the money I will bet you feel really good too.

[fdunford]

You have to love the age we live in with tools like this forum and the search feature!

On Friday my fan died (except high). I did a search that night and read this post. I found a resistor pack at NAPA, Part Number BR223 for $21.49 and had it fixed on Saturday.