How do you fix this? (Blower plug)

[gijoecam]

I was having issues with my blower motor not working properly. In the first two positions on the fan switch, the front motor ran in low, the rear would only run in the middle or high position (i.e. the rear would not run with its switch in low). The fans would both work normally in their highest two settings. I was under the assumption that it was a problem with the front blower resistor pack as I'd had trouble with it a long, long time ago. Boy was I wrong. The resistors are fine. Now I need to figure out a way to fix this:

The only thing I've come up with so far is to find a wrecked one in a bone yard. They've used that same resistor pack on most of the Ford vehicles for the last 10 years, so it shouldn't be too difficult to find. Does anyone have any other suggestions? Any possibilities someone's got that piece of the wiring harness laying around that they don't want?

I need to get 'er back up and running ASAP. Thanks, gang!

-Joe

 

[gijoecam]

Just took a closer look at the resistors.... not good, not good at all....

Help?!!? I'm at a total loss here.....

 

[Interstate]

Those look corroded beyond repair. I would suggest that you try to find an OEM replacement. But it looks as if you'd have to buy an entire bundle which costs a lot. (but it wouldn't hurt to look) Otherwise, you could go to a junkyard or spare parts place and just cut those connectors off, an replace your damaged ones.

Maybe try shrink-wrapping to prevent moisture from entering so easily.

 

[Brian_B]

I would check the wiring further back from the connectors as well. From the look of them they have been rusting for a long time. Rust in wiring makes heat which probably melted the other connector.

If you get some from a salvage yard, cut the wires as long as you can. Then replace as much of yours as possible. You may have other electrical problems before long too. Now at least you know what to look for.

 

[steve.ryan]

check your local salvage yard. Can't find one, let me no. I've got a couple parts explorers i would be happy to help. Don't want nothing.

 

[gijoecam]

check your local salvage yard. Can't find one, let me no. I've got a couple parts explorers i would be happy to help. Don't want nothing.

I plan on calling the dealership I used to work at as I remember we used to collect salvaged harnesses just for times like this.

The insulation on the two bad wires is split and you can see the oxidation on the wire strands, so I had planned on hacking off as much as humanly possible (if I can find a connector that's not trashed as well). The new resistors were a whopping $15.... just never thought I would need the connector too.

I'll let ya know what I find, and may have to take you up on the offer. Thanks!

-Joe

 

[DeRocha]

You can try and get new connectors from a bone yard and splice them in place. If not cut the wires from the connector (its obviously junk) and replace with new wiring (same or better guage).

 

[gijoecam]

You can try and get new connectors from a bone yard and splice them in place. If not cut the wires from the connector (its obviously junk) and replace with new wiring (same or better guage).

Turns out the stealership also sells pig-tails for that part. Apparently I'm not the only one that's had this problem before. $15 for the resistor pack, $15 for the pig-tail. I'll be heading down there in about 5 minutes to see if it's the right one.

I'll let everyone know if it works. I'm sure I'm not the only Explorer that's had this happen before. It's another high quality Ford design...

-Joe