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Technical / Installation Articles - Body Interior / Exterior

Blower Motor Resistor Fix

Article written by Dr. Jones

Date Added: 08/23/2009

Got a 97-99 TJ with a bad blower resistor? We?re going to save you up to $60.

Does your blower motor have two speeds, high and off? Chances are good you?ve got a bad blower motor resistor. Good news, it?s an easy fix. Bad news, the dealership wants over $60 for the part.

At least that's what our local parts department decided this little platinum and jewel encrusted gem was worth. Some of you may be lucky enough to have a stealership that only wants $40. Others may be even luckier and find one at a parts store for about $25. That price is much easier to swallow, yes, but what if we told you that you can fix your old resistor for $1.95. That?s better than $25 and a helluva lot better than $60.



1. Start by removing the kick panel on the passenger side under the dash with an 8mm socket.

2. Don?t forget the two on the bottom.

3. With the kick panel out of the way, the resistor is easily accessible. Slide the red plastic clip back, and remove the connector.

4. With an 8mm again, remove the two screws holding the resistor.

5. Carefully remove the resistor.

6. Here is the resistor out of our Jeep. Make sure yours is this style, not the thin credit card type, before trying to fix it.

7. With needle nose pliers, bend the tabs holding the cage on the resistor and remove the cage.

8. With the cage removed, we can clearly see the thermal fuse. This is the part of the resistor that fails most of the time and is our $2 fix. With a volt/ohm meter, check for continuity across the fuse. If you have no connection, the fuse is bad and lucky you, the resistor can be fixed.

9. Head over to your local Radio Shack, or other electronics supplier, and pick up a new thermal fuse. Make sure you get one with a similar heat range to the 130°C the factory fuse is.

10. Cut the bad fuse out with wire cutters. Cut close to the fuse so you have some wire left over to work with.

11. Rather than risk blowing the new fuse while soldering, we?re suggest using crimp on connectors.

12. Remove the plastic from the connectors so it doesn?t melt while in use on the Jeep.

13. Crimp the new fuse in place. Make sure the colored cone end is oriented the same way as the old fuse (pointing left in the picture).

14. Carefully put the cage back on checking the fuse for clearance.

15. As one final test before installing, check for continuity between the outside pins on the resistor. If you have a connection, put the resistor back in the Jeep.

Final Thoughts

Success! We have all 4 fan speeds again. And we saved $58.02 by not supporting our local stealership parts department.

Disclaimer: If your resistor is fried in some other way, this won?t fix it and you?re going to have to cough up the money for a new one. But 90% of the time this will work, and for $2 it?s worth trying. Also if you have a newer TJ, your resistor is different and this won?t work. But your part is cheaper so stop complaining.


Purchase / Vendor Info

Vendor Name: Radio Shack
Phone: 800-843-7422
Website: http://www.radioshack.com

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