Happy New Year everyone!

Although I didn't receive any responses on rebuilding/repairing the blower motor resistor pack, I managed to do it! The pack of resistors needs to be replaced as a unit, but that wasn't the cause of the problem. The cause was the thermal protection fuse in series with the +12V into the resistor pack module. I bought a new one at Radio Shack, soldered it in (using a heat sink so as not to overheat the fuse and blow it during soldering), and presto, my fan works on all speeds.

For the thermal fuse to blow, the unit had to get really hot. The cause? severely oxidized connectors. I used trimmed nail files to remove the oxidation from the spade connectors on the back of the resistor pack module (they were black and green!), applied plenty of DeOxit, and finally some dielectric grease before reinstalling.

Steve Ringlee, if you see this, this might be a good candidate for the FAQ.

See cruddy pictures referenced

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/IMAGELIB/images/4358.jpg

Chris
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1991 Volvo 945Ti @ 0.327 million kms, in Ottawa, ON, CANADA