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I have a ‘92 F150 and a ‘93 F250, neither with A/C. On both, the fan will only run on the fastest switch setting. On any other switch setting the fan does not run.
Is this a common problem on the early ‘90's trucks? My personal fleet has it with 100% of the trucks.
Any ideas? Replacing the fan motor on one did nothing.
There is also a resistor in the wiring to the fan from the switch. Its mounted in the ducting in the engine compartment (two screws and one electrical plug to remove it). I've also seen the contacts in the switch burn up after some years of use.
I just checked with NAPA, thiers is 25.00 for the resistor pack, I cant imagine what the dealer would want for it, maybe your first born.
I took mine out and checked the resistance on the resistor, its almost nothing. I took a piece of copper wire and bridged where the resistor was and it seems to work fine, but I am no expert.
I know it has to be a high watt resistor, I tried just replacing the resistor with a 1/2 watt one and it burned right through it. I was thinking about trying one of radio shacks 20 watt resistors, but they are about 5 bucks and if it did not work, its just that much closer to replacing the resistor pack.
You could always try the salvage route. Go to a local yard (with your old resistor assembly in hand) & get a few resistors assemblies: The law of averages says you will find at least one that works - probably a couple, then you will have a spare. Remember, you need not confine your search to F-Series, as most FMC vehicles from these years should be compatible. The one exception would be high end/luxury vehicles with the ATC (automatic temperature control) system.