did searches and can't find anything. In any setting - A/C, Max A/C, defrost etc - the blower works fine on the highest setting, but in the other settings NO air moving at all. Any ideas ???

 

It is your blower motor resistor. Easy to change, it is on the firewall by the blower motor.

 

Common problem on some previous vehicles of European origin that I have owned, not as common on the SDs though. However, as CurtisFT said, it is an easy fix.

Here is the location:



And the original Ford PN is 4C2Z 19A706-AA, but an equivelent DORMAN replacement can be found on Amazon for less than $13 or just over $16 for an OEM one on RockAuto.



...why yes I am at work and slightly bored.

 

When I had to replace mine the plug on the wiring harness was also melted. I was able to get a replacement at auto zone that had the plug and approximately 10" of the wires.

 

One of the suppliers I saw also provided a replacement plug with the resistor module, must be a common event for the plug to melt then. One of my old cars I had years ago also melted down the connector when the resistors fried. For that car I had to go to Radio Shack and buy some heavy duty resisters and solder them in since the OEM replacement was over $100.

 

thanks for all the help guys. It was that relay, but the plug had gotten knocked loose !~

 

Now that's a really cheap fix! Always like it when something is easier than you expected. Thanks for the follow up.