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Coming home from the shore and turned of the air but not blower. No speeds at all. Fiddled with it until I got to a rest stop. KOEO, tapping the blower did nothing and swapping relays did nothing. 40 amp fuse and inside #22 ok. Had some time last week and discovered that power to blower was intermittent. Pulled the resistor pack plug and it was partially melted and upon removal of resistor pack I could see it was toast. Replaced that and pigtail and still got intermittent blower and intermittent voltage at blower connector.
Days go by with only a chance of it working but noticed it turned on more when I started the truck with the blower motor switch turned on. Maybe bad contacts somewhere or maybe loose connector in harness I thought.
I had been meaning to replace some burned out cluster bulbs with new LED's, so I bought a motor switch and did both items. Left the front dash part off because nothing changed as far as the blower was concerned.
I downloaded the schematic to end the frustration and see the power going into Mode Selector switch, black/yellow. My test probe gets nothing through insulation with KOEO. Pulling the connector and probing the contact of the blk wire and I get blower all speeds but no light glowing from test probe as if I just grounding it. I have to add that 1/2 the time I got not blower and 1/2 the time I did, so It was intermittent there as well. Doing this again several times while restarting the key to run and still the same until after about 8 times, I finally get a light on the probe, probing the wire while its connected and I get it now with it disconnected and all seems ok. I have blower each time for the last dozen restarts and I cant make any sense of it.
I just have a feeling this good heat isnt going to last. Should I replace the Mode Selector Switch? Any ideas ? It seems the relay coil wasnt energizing but now it is. Last week I shot the relay seat with contact cleaner and replaced it with new napa one out of frustration.
I had this problem a couple years ago. Ended up the connector where the wires go into the blower housing were corroded a little. Didn't look that bad to me, but I cleaned them up and problem never came back.
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