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On my '94 Aero XL ext with 3.0L, for years now on the front drivers switch for the medium selection for the rear heat/ac fan hasn't worked. I am sure this is only happening on the front drivers switch. If you use the rear passenger switch, it works from low thru medium and high. So I am now wondering if anyone else has had this problem, maybe some obviouse little problem before I splash out for a new switch.....I'm assuming I need a new switch. Maybe a broken wire, but probably not likely. Its been broken for more years than it worked! As you are probably well aware that using the high selection is way too noisy after a minute of it. So we have to stick with only the low selection from the front switch for the rear fan, in order to carry out conversations with people in the rear. We've put up with it this long, but figured I may try fix it this year, since the weathers heating up again and the first thing we are doing now is throw the a/c on and all the fans. It would be nice to move more air in the rear with the medium, quieter fan selection, but a little faster than low. And of course trying to coordinate one of the kids or a relative in the back to operate the controls at the desired selection is near impossible without me driving off the road somedays!
I'm affraid you are going to have to bite the bullet and take the
cover off the dash that holds the switch. It should not be that hard. There are a couple of screws and some 'POP Clips'.
The problem is, you have to take off other covers to get to that cover.
Once you have them off, you can troubleshoot the switch. Check to see if power or continuity continues through the switch. The easiest way is with a digital multimeter. You can either check for voltage or make sure the contacts short the wires when it is in the desired position. I'm not sure, but I'm assuming there are 3 to 4 contacts on the switch.
Find out which one is common to all the others, and you have it licked.