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On my wifes 94 Explorer the blower for the heater and AC has been cutting out. I turned off the AC and just ran the fan and it runs for awhile then cuts out seems to do it more often on high when the fan is maxed out. Living in Arizona the AC gets used a lot. I checked all fuses dealing with the blower. I checked the blower motor resistor and it was fine. I check electrical wiring under the hood around the motor and did not find and problems. I took the blower motor out and the motor itself seemed to be okay it would spin with no problem. Could it be the blower motor switch on the dash? I don't think it cuts out when I hit bumps in the road, but my wife seems to think that has something to do with it, she drives it more than I do. It does seem to do it more often when it is real hot out. I am stumped on this one. Anyone have any ideas on a fix. Thanks for the help.
Since it is intermittent it would be hard to say, but the motor may have a burned pin in the connector you arent seeing and when it gets hot the circuit opens. Also the resistor can look good but have rust in where the wires contact and intermittently fail to connect, as well as possibly the switch. Look down in the blower motor socket real close and see if the plastic that surrounds one or both of the blade pins looks melted around it. It could be that the brushes have just worn to a point that they are intermittently failing to contact.
I am going to go ahead and replace the blower motor just to be sure. I ran a continuity test on the blower motor resistor and it was fine. If the blower motor doesn't do it I will check the inside switch. From there, I guess I will replace the resistor, it has a thermal limiter that may be the problem. I will let you know what happen after I replace the motor. Thanks for the suggestions.