Fan Resistor Wiring

[willymutt]

So I've replaced the fan wiring connector and resistor for the second time now. The first time I didn't do them at the same time so I assumed one it caused it to go bad so I replaced both at the same time about a month ago. It is starting to fail again now. It wouldn't be so bad but this is my wife's vehicle and it has been 90 plus for the last few days. She isn't as patient as I am. Any tips on fixing it again?

 

[Millerwelds1]

Following

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[99WhiteC5Coupe]

So I've replaced the fan wiring connector and resistor for the second time now. The first time I didn't do them at the same time so I assumed one it caused it to go bad so I replaced both at the same time about a month ago. It is starting to fail again now. It wouldn't be so bad but this is my wife's vehicle and it has been 90 plus for the last few days. She isn't as patient as I am. Any tips on fixing it again?

Did you use the OEM Ford part specified in this TSB: https://static.nhtsa.gov/odi/tsbs/2019/MC-10156877-9999.pdf

 

[Trainmaster]

Follow 99Coupe's suggestion and make sure your connections are soldered and the pins are good and clean.

 

[Yupster Dog]

Is the A/C condensation drain clogged? Is it possible that water is getting in the duck and causing this?

 

[Jeff12345]

This doesnt solve the long term problem but what I've found is that the max setting overloads the resistor, shutting it down til it cools (I assume this is what's happening) as it dies. I've got my 3rd one waiting to go in, but in the meantime I shut off the auto setting and keep the fan to the middle range settings the resistor will function til you can replace it -- and thus keep the wife happy(er).

My 2 cents.

 

[OGBobbyJohnson]

blower motor inside or exterior electric fans? my exterior fans sound like a jet engine.

 

[willymutt]

I did not use the Motorcraft parts this time but have in the past. The resistor isn't failing, just the electrical connection. It is inside the passenger compartment.

 

[2010ELExpy4x4]

I had the same problem with our 10, I ended up adding (with special glue)a heat sink (computer processor type) to it and then had to modify the hole in the plenum, haven't had any more issues. We just drove from southern ca to northern nev in July. Is a bit of work though.
I tried aftermarket resistors and motorcraft didn't make any difference. I also modified one with ballast type resistors to no avail.

 

[Millerwelds1]

Do you happen to have a picture of this heat sink you added?

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[2010ELExpy4x4]

Jeff I found the resistor is not used on the highest fan setting, when ours went high was the only setting that worked, after tracing the circuit that was confirmed.

 

[2010ELExpy4x4]

Here are pictures most difficult is making hole bigger in plenum, I had already modified it when I made my own module out of ballast resistors, which didn't work any longer than stock. The resistor is cooled by the air passing over it. It doesn't seem it can dissipate enough heat being flat.

 

[2010ELExpy4x4]

Special heat sink adhesive