I own a 1990 E-150 5.8L. I call her "The Beast". I had the air conditioning repaired during a trip to Houston, TX. The blower motor, relay, and resistor were replaced along with new connectors (Which I had). I have a dual system. Everything worked great for a few days then nothing. The selector switch did nothing. Whether it is at low speed or high speed it blows on low speed. Just barely blowing. I did the troubleshooting this time and found a burnt resistor. Maybe a bad part, maybe not. I replaced it and the problem reappeared. After checking wiring, connectors, I was totally shocked to find that apparently, the AC mechanic had failed to put the baffle back in with the resistor. The resistor was burnt again. $50 give or take for two resistors, I need a baffle, and cannot locate one. Baffle Part number E9TZ-19A706-A. I have tried the online salvage yards, parts locator, and my goodness!, I've been bombarded with emails for everything but...
Hopefully, someone out their has some info to steer me in the right direction or knows a place with vintage, old, antique, OEM parts, or aftermarket

 

Your part number come back to the resistor unit for an air-conditioned E150. No mention of a baffle. I replaced the resistor in my 94 and the resistor, while in the airflow, had no baffle. The motor is the sole current sinking device in this instance. Did the shop supply you a new blower? Did you have the same failure before the shop repair? If you have a DC current meter capable of ~20 amp I would run the fan directly off the battery and see what the average current is.Guessing, I'd say 10-16 amp would be normal. More than that I would suspect the blower motor. Rock Auto has OEM motors for $32(w/o fan) and resistor networks for $13. Hope this helps.

 

Hey Jeff, I really got tied up and I am sorry to keep you hanging. My Bad, I listed the wrong part #. Baffle # E9UZ - 19024-A.

 

Searching Google showed this as the 1st item Deflector. I don't see the relationship between this missing and the fuse blowing. Order one, install it and let us know how it went.

 

i have same problem on my 99 e250, i replace it 2wice a year. get one from autozone gaurenteed for life so its free everytime.
the fan control switch. itll get stuck in one position then if you move it, its toast

 

UPDATE... I was searching by part name in the repair manual. Deflector is the correct name. I ordered it, installed it. Perfect. It was not blowing the fuse, the resistor itself was overheating. I replaced two of them at @ $25 each.Amazing how this works. I am assuming it creates a vortex inside the plenum to keep the resistor cool. I live in south Texas, San Antonio. The A/C pretty much runs 24/7 here. Thank you for your assistance, Jeff!