How To: Replace blower resistor

hyedipin · **Joined:** Thu May 11, 2006 10:20 am **Posts:** 1667

When you have only some of the fan speeds working on your A/C - Heater and others are not working (Generally 1-2 not working while fan 3 and 4 work)

Quote:

REMOVAL
WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS,
DISABLE THE AIRBAG SYSTEM BEFORE
ATTEMPTING ANY STEERING WHEEL, STEERING
COLUMN, OR INSTRUMENT PANEL COMPONENT
DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE
THE BATTERY NEGATIVE (GROUND) CABLE,
THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM
CAPACITOR TO DISCHARGE BEFORE PERFORMING
FURTHER DIAGNOSIS OR SERVICE. THIS
IS THE ONLY SURE WAY TO DISABLE THE AIRBAG
SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS
COULD RESULT IN AN ACCIDENTAL
AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.

(1) Disconnect and isolate the battery negative
cable.
(2) Open the glove box door to gain access to the
blower motor resistor.
(3) Pull out the lock on the blower motor resistor
wire harness connector to unlock the connector latch.
(4) Depress the latch on the blower motor resistor
wire harness connector and unplug the connector
from the resistor.
(5) Remove the two screws that secure the resistor
to the HVAC housing.
(6) Remove the resistor from the HVAC housing.
INSTALLATION
(1) Install the new resistor in the HVAC housing.
(2) Install the two screws that secure the resistor
to the HVAC housing and tighten to 2.2 N·m (20 in.
lbs.).
(3) Plug in the blower motor harness connector.
(4) Push in the lock on the blower motor resistor
harness connector.
(5) Close the glove box door.
(6) Connect the battery negative cable.

Click on images for full size picture.

On the package it said "Made in USA" but inside, it says "Mexico".. :confused:

You need 5/16 key to unscrew.

Disconnect Battery Negative

Remove the Glovebox by sliding it to right.

Remove the Panel, otherwise you may not have enough room to unscrew the second screw.

Pull it down

Located the Resistor Harness

Pull the red lock (the picture shows it already pulled).
And pull the wiring harness.

Unscrew the top screw using a driver, and the bottom using a key since driver won't fit there, this is why I had to remove the panel on mine.

They look a little different, notice the jel, probably to increase conductivity? (On the Stock one, replacement does not have the jel)

Close-up.

Install and Screw it back, picture from the bottom.

Follow reverse order and complete.
Connect negative back.. At this point I heard a "Pop" from somewhere inside, I don't know if something popped or went back, I am not sure, but I tried the blower, it was working on position 1. I did not take the Jeep for a spin since I had just washed it and it started raining.. Will report back tomorrow if the jeep runs at all!

Liberty for All · **Posted:** Fri Dec 26, 2008 12:48 am

Thank you for the photo instructions. I did mine today and did hear the pop after the battery lead was connected. Must have been a reset. All four fan settings now work fine.
The only trouble I had was pulling the wire harness. The red clip was tough for me to pull. It slides not lifts up as you described.
The parts guy at the dealer said that all Chryslers need this part replaced.
The Made in Mexico but on the package Made in USA is allowed I think because of NAFTA regulations which permit saying so. Bad quality, this part should be more reliable. My 2005 Sport is only three years old and low milage.

:)

racnee · **Posted:** Fri Dec 26, 2008 4:07 pm

How much did this part cost you? I went to my local dealer for some parts and they were way more than people here had stated. there is only a couple dealers neearby.

Liberty for All · **Posted:** Sat Dec 27, 2008 7:09 pm

racnee wrote:

How much did this part cost you? I went to my local dealer for some parts and they were way more than people here had stated. there is only a couple dealers neearby.

Here in North California the dealer parts charged me $30.. The part comes from the Chrysler warehouse here and like the one in the instructions, is made in Mexico but the package says made in USA.
Maybe this is why it failed so soon. The parts guy said they sell many of them regularly. Chrysler better get their act together if they want to survive.
At least it was a cheap fix.

hyedipin · **Joined:** Thu May 11, 2006 10:20 am **Posts:** 1667

ebay has it for $27, that's where I got mine from (the seller is a Chrysler dealer)

hyedipin · **Joined:** Thu May 11, 2006 10:20 am **Posts:** 1667

Liberty for All wrote:

The only trouble I had was pulling the wire harness. The red clip was tough for me to pull. It slides not lifts up as you described.

Hey Liberty for All,
The picture I posted is from the bottom of the red tab, so it looks like "lift" but actually it is sliding towards the seat. So when you are looking at it from the bottom, you pull it towards the seat, making it look like lifting on the pic.

Pote · **Posted:** Tue Dec 30, 2008 5:22 pm

hyedipin wrote:

When you have only some of the fan speeds working on your A/C - Heater and others are not working (Generally 1-2 not working while fan 3 and 4 work)

Quote:

REMOVAL
WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS,
DISABLE THE AIRBAG SYSTEM BEFORE
ATTEMPTING ANY STEERING WHEEL, STEERING
COLUMN, OR INSTRUMENT PANEL COMPONENT
DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE
THE BATTERY NEGATIVE (GROUND) CABLE,
THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM
CAPACITOR TO DISCHARGE BEFORE PERFORMING
FURTHER DIAGNOSIS OR SERVICE. THIS
IS THE ONLY SURE WAY TO DISABLE THE AIRBAG
SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS
COULD RESULT IN AN ACCIDENTAL
AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.

(1) Disconnect and isolate the battery negative
cable.
(2) Open the glove box door to gain access to the
blower motor resistor.
(3) Pull out the lock on the blower motor resistor
wire harness connector to unlock the connector latch.
(4) Depress the latch on the blower motor resistor
wire harness connector and unplug the connector
from the resistor.
(5) Remove the two screws that secure the resistor
to the HVAC housing.
(6) Remove the resistor from the HVAC housing.
INSTALLATION
(1) Install the new resistor in the HVAC housing.
(2) Install the two screws that secure the resistor
to the HVAC housing and tighten to 2.2 N·m (20 in.
lbs.).
(3) Plug in the blower motor harness connector.
(4) Push in the lock on the blower motor resistor
harness connector.
(5) Close the glove box door.
(6) Connect the battery negative cable.

Click on images for full size picture.

On the package it said "Made in USA" but inside, it says "Mexico".. :confused:

You need 5/16 key to unscrew.

Disconnect Battery Negative

Remove the Glovebox by sliding it to right.

Remove the Panel, otherwise you may not have enough room to unscrew the second screw.

Pull it down

Located the Resistor Harness

Pull the red lock (the picture shows it already pulled).
And pull the wiring harness.

Unscrew the top screw using a driver, and the bottom using a key since driver won't fit there, this is why I had to remove the panel on mine.

They look a little different, notice the jel, probably to increase conductivity? (On the Stock one, replacement does not have the jel)

Close-up.

Install and Screw it back, picture from the bottom.

Follow reverse order and complete.
Connect positive back.. At this point I heard a "Pop" from somewhere inside, I don't know if something popped or went back, I am not sure, but I tried the blower, it was working on position 1. I did not take the Jeep for a spin since I had just washed it and it started raining.. Will report back tomorrow if the jeep runs at all!

darn, I literally just paid $65 bucks to have it replaced. oh well....and yup, no fan on 12or 3, 4 was blowing fine. not fun on a 2 degree day.....driving with the heat on full blast and the windows down. lol

hyedipin · **Joined:** Thu May 11, 2006 10:20 am **Posts:** 1667

Hey Vatiiva brother, you are lucky.. Dealer quoted me $300 to $350 for it with labor~!!!

HoppedUpOnGoofballs · **Joined:** Sat Nov 29, 2008 10:36 pm **Posts:** 203

Great write-up..

Anyways, the part is actually hecho en mexico, but the bag is made in the USA.. So that explains those markings. :lol:

jpelej · **Joined:** Sun Apr 02, 2006 10:20 pm **Posts:** 6

I replaced my resistor tonight after loosing both the 1 and 2 speeds on my fan. The dealer charged $32.00 for the part and it took me about 30 minutes to install. The directions on the forum were great. The only thing that sucked for me was getting the original resistor off the harness. The red lock wouldn't budge. I ended up unbolting and pulling the old resistor out before unhooking it from the harness. This allowed me to stick a slotted screwdriver into the back side of the locking mechanism holding the harness and resistor together. In other words, I sort of bypassed the red lock by lifting and pushing it out. Once that was complete, I ended up having to use a pliers to grip the harness while pulling on the resistor. The old resistor was really chalky on the inside and was almost dry welded to the harness. I guess I am not surprised given how hot the part gets during normal uses. Putting everything back together was breeze. Hopefully the new one will last more then 3 years.

LibertyN8 · **Posted:** Tue Feb 17, 2009 3:50 pm

I have not been on the forums for awhile now, but it sure is nice to know when you have a problem with somthing LOST KJ's is there for you!

I went to my dealer with this today and he wanted to replace my blower motor! I bought the part for 20.37 and took 20 mins to install it. fan works great. Thanks for the great post and helping me out!

Later-N8

hueyflyer · **Joined:** Sat Oct 01, 2005 10:10 am **Posts:** 19

Thanks for the great instructions. I replace mine this morning in less than 1/2 hour. Only problem I had (like others) was getting the red lock to slide out. I also pulled the resistor our still attached to the plug and finally got the lock to slide using a flat screwdriver. My wife has a Olds Alero and I have changed these three times on it. At least a two hour job as the blower has to be dropped to get at it. Much easier on the Libby.

Donkeykong · **Posted:** Fri Aug 21, 2009 6:18 am

I haven't been here in a while, but thanks for the writeup, I was mooching around behind the center console... had the radio out and all.... I knew I would be making a visit here this AM

104,000 miles on my 06 and counting.

LibertyFever · **Posted:** Sat Aug 22, 2009 9:51 am

HoppedUpOnGoofballs wrote:

Great write-up..

Anyways, the part is actually hecho en mexico, but the bag is made in the USA.. So that explains those markings. :lol:

LOL...I was going to suggest the same thing :lol:

Liberty for All · **Posted:** Thu Jan 14, 2010 8:18 pm

Donkeykong wrote:

I haven't been here in a while, but thanks for the writeup, I was mooching around behind the center console... had the radio out and all.... I knew I would be making a visit here this AM

104,000 miles on my 06 and counting.

Hi,
I want to ask what other problems or fixes you have done to your 6 speed trans or other parts of your KJ.
Are you satisfied with the reliability?

I have an '05 with manual and 4x4.

jafstl38 · **Posted:** Fri Jan 29, 2010 4:05 am

My fan only works on 4, so its pretty much all or nothing, is this the same problem you all are having?

Liberty for All · **Posted:** Mon Feb 01, 2010 5:19 am

Yes, this is the same problem but the fix is do able yourself as detailed here.

e_poirier2004 · **Posted:** Wed Apr 21, 2010 2:34 pm

Maybe you should consider using an upgraded blower resistor from a 2001-2004 Sebring if you don't feel like redoing that job all over again in less than a year... See this post:http://www.lostjeeps.com/forum/phpBB3/viewtopic.php?f=3&t=47156&hilit=blower+resistor

Liberty for All · **Posted:** Tue May 04, 2010 12:00 am

Wow, and it still works?
Thanks for some brilliant research and testing. :goink:

e_poirier2004 · **Posted:** Sat May 22, 2010 3:29 pm

Works like a charm and bolt-on! For some reason, ($$$$$) they did the upgrade on the sebring but not on the liberty!!!! The upgrade is a much stronger design.

How To: Replace blower resistor

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