A/C blower fan intermittent

[IslandSport94]

I posted this once before and got no replies, so here goes again. My blower fan seems to only work when it feels like it. When it is working, it works at all speeds. Usually, at first start-up of the day, it will work fine. If I re-start after a short stop, it won't come on. It will then start/stop working at random. Yesterday, in a fit of confusion and frustration, I replaced the resistor pack. Still same problem. This is especially frustrating since I recently spent over $600 getting the A/C system replaced.
So, what could it be? Motor, switch, relay? Anyone have a similar problem? I aint rich, so throwing $60-70 parts at the problem is not the best option.
Thoughts?

 

[TPLYNCH]

Try replacing the relay in the power distribution box under the hood.

 

[IslandSport94]

Thanks, Tom. I just did that this morning at work and it seems to be working. Time will tell, I guess.

 

[orion1998_1]

where did you get the relay how much was it?

 

[IslandSport94]

AutoZone, $12.95. Works like a charm.

 

[orion1998_1]

i called mine(see my blower motor thread) they said they didnt carry it yiou have a model - part number please

thanks

 

[Jason94sport]

Yeah relay problem. Mine did that. Replaced it, been fine for a year now. I got mine from Ford. Just take it with you to the parts counter. They should be able to match it up. If you want to test it there's a relay to the right of the blower motor one. It shuts the AC off at WOT. You can swap that one in & see if it works.

 

[orion1998_1]

as in my post i have the under hood fuse box, but there are no relays in it, i'll try to get a pic tomarrow

 

[Island94]

I have been having this intermittent blower fan problem and following related threads for about a year now, but had nothing useful to add... until now.
I took this advice and replaced the relay - and have not had a problem since. Total cost - $7.77 from Checker.
Two notes:
1) The WOT relay appears to be a different part number, and the only relays with the same part number seem to be for the ABS break system... therefore I did not switch over the relay to test the part before buying a new one.
2) Within an hour of driving with the new relay, I smelled a burning plastic smell... but it then went away and everything continued to work properly. I assume it was just 'burning in' the new part.

When I went to the Ford dealer for the problem, all they said they could do is run a diagnostic (which would cost $80-90), which may or may not determine what the problem is. Seems like they need to have some researchers following the forums and advising their tech support.

Thanks to this community for the help!!!