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  1. #1
    Join Date
    Jan 2001
    Posts
    7,814

    Ford E-150 blower resistor pack

    Anyone know where this located on a 2002 Ford van.

    My blower only works on the lowest speed setting...which from my reading would mean that either the switch or the blower resistor pack is bad.

    Ive been reading on the net and I see more hits about blower resistor packs being bad than selector switches being bad so Im wanting to hunt down the resistor pack and check it.

    I know its supposed to be somewhere in the ducting off the blower but was hoping someone could help me pinpoint it.

    I did see a wiring harness going to the blower housing itself... so Im thinking it could be it... I just hate taking things apart on a company van but I gotta get this fixed before long or I wont have a defrost.

    Also, I keep reading on the net about fans being stuck on high when the resistor pack goes bad but my fan is stuck on low...

    Just throwing this out there in case anyone else with an older Ford has run into this problem... No biggie.... I'll just start ripping things apart in the morning....lol

    thanks

  2. #2
    Join Date
    Feb 2007
    Posts
    534
    On the 1999 It is located behind the battery on the wall. You must remove the battery and the battery tray to gain access. It is held in with two 5/16 screws.

    First look behind the A/C accumulator .
    If it doesn't go easy, you are not using a big enough hammer.

  3. #3
    Join Date
    Jan 2001
    Posts
    7,814
    I found it. It is right on the end of the blower housing...

    Just got to remove the battery and the battery tray to get to that bottom screw....lol

    great.

    thanks

  4. #4
    Join Date
    Feb 2007
    Posts
    534
    Your welcome.
    If it doesn't go easy, you are not using a big enough hammer.

  5. #5
    Join Date
    Nov 2006
    Location
    Southeastern Pa
    Posts
    18,557
    Let us know if you find an open resistor. I never had one in the hundreds of E's and F's I worked on.

    But, there is a first time for everything.
    [Avatar photo from a Florida training accident. Everyone walked away.]
    2 Tim 3:16-17

    RSES CMS, HVAC Electrical Specialist

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  6. #6
    Join Date
    Aug 2007
    Location
    WI
    Posts
    1,110
    Quote Originally Posted by corny View Post

    Also, I keep reading on the net about fans being stuck on high when the resistor pack goes bad but my fan is stuck on low...
    Hmm, that is what my '03 E350 does. I've been living with it for over a year now, but you've inspired me to fix it.

  7. #7
    Join Date
    Nov 2004
    Location
    Skokie , IL near chicago
    Posts
    1,133

    same prob....

    Quote Originally Posted by corny View Post
    Anyone know where this located on a 2002 Ford van.

    My blower only works on the lowest speed setting...which from my reading would mean that either the switch or the blower resistor pack is bad.

    Ive been reading on the net and I see more hits about blower resistor packs being bad than selector switches being bad so Im wanting to hunt down the resistor pack and check it.

    I know its supposed to be somewhere in the ducting off the blower but was hoping someone could help me pinpoint it.

    I did see a wiring harness going to the blower housing itself... so Im thinking it could be it... I just hate taking things apart on a company van but I gotta get this fixed before long or I wont have a defrost.

    Also, I keep reading on the net about fans being stuck on high when the resistor pack goes bad but my fan is stuck on low...

    Just throwing this out there in case anyone else with an older Ford has run into this problem... No biggie.... I'll just start ripping things apart in the morning....lol

    thanks
    on my 02 explorer , use a mirror and check under the blower motor , it is held in with 2 screws and will be the hardest job you can imagine. mine stayed on low speed until high and then worked on high. i did it my self 'cause ford wanted $130.00 to inst. a $17.00 part..good luck..Jack

  8. #8
    Join Date
    Jan 2001
    Posts
    7,814
    OK, this evening I finally got a chance to check this out.

    Actually ...this morning I pulled the battery and battery tray and got to the resistor pack.

    Everything seems fine with the resistors.... All contacts were corroded and the studs thatthe resistors mount on...and the resistor leads themselves are corroded a little...

    Cleaned on these connections for a while then had to slap it all back together.

    I got sent on a call and had to toss everything back together...didnt get back to the shop till late in the a noon....

    Went out there tonight and pulled the radio then got the plug off the fan switch. The fan switch and connector have melted.

    I did a little checking with my meter and a jumper wire and ended up jumping out the common ground to the med high speed wire.... they are all grounds....evidently ford uses a single speed motor and the resistors in series with the ground thru the switch....control motor speed.

    I wire nutted the wires together and then just sat out in the van for about 30 minutes...cleaning the cab...looking thru some of my books and papers....all the while feeling the connection to see if it was getting hot.

    It got warm....but no warmer than a would think a factory wire and connection would get pulling those fan amps.

    Anyone got an easy way to get the switch itself out ??? Just getting the connector out almost needed three hands...but I finaly got it..... Used a mirror and flashlight to try and see how the switch is mounted but I cant see anything....anything usefull... tried pulling it out and it wont come.....

    Im fine with my fix for now....but Im going to have to replace that switch....

  9. #9
    Join Date
    Dec 2007
    Location
    Northeast Wisconsin
    Posts
    482
    Quote Originally Posted by timebuilder View Post
    Let us know if you find an open resistor. I never had one in the hundreds of E's and F's I worked on.

    But, there is a first time for everything.
    I had to replace the one on my old 2000 E150. Also one on my 2001 Express 2500.

  10. #10
    Join Date
    Dec 2003
    Location
    Citrus County, Florida
    Posts
    1,551
    You may find that the fan motor is pulling too much current because of worn bearings.
    Doug

  11. #11
    Join Date
    Nov 2008
    Posts
    1,673
    Melting means high contact impedance. One of these fans may pull 30A and 30A at 0.01 ohm is a lot of watts for a connector to dissipate.

    There might be a recall on this switch or assembly. Check NHTSA and the Center for Auto Safety. Or, you can get a switch from Digi-key or Allied Electronics that is probably much more reliable.

  12. #12
    Join Date
    Dec 2008
    Location
    Buffalo NY
    Posts
    3,107

    Cool

    I had to replace my switch this on my 98 E-250. Pretty easy. Just pulled the cover and changed it in autozones parking lot. Came apart easy because I caught the small fire while I was driving and shut it off. It is scary when you see smoke coming from behind you dash.
    Join http://scopeny.org/ Shooter’s Committee on Political Education

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    Support the Skilled Trades, Don't DIY

  13. #13
    Join Date
    Apr 2004
    Location
    Muskegon, Mi.
    Posts
    425
    Just suck it up and get one of these.

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