I have replaced the fan switch on the dash about 3 times so far since I bought my van.
The connector was slightly melted .
The latest switch worked only for a day or so, and then very intermittently - like once every two weeks.

I have checked the fuses inside and in the main power pox in the engine compartment.
I have also pulled the relay in and out and hear it click when I put it back.
I'm guessing that it means it's working.
Anyone think it could be the blower motor.
The only other thing I could think of the the selector switch for vent/defroster/floor etc.
I have 280k miles on the van.
Thanks for any thoughts.

LJ

 

check the plug on the blower motor mine does the samething, one of the 2 clips got broken off when the dealer put one in and it just moves a slight bit enough to not make a connection

 

Hi,
I removed the plug a few times to see if that was the problem - didn't do anything, however, I finally found my volt meter and took a reading at the plug. It has voltage, so it looks like it's the blower motor. I went out and bought one and hopefully will have some time to install it over the next few days.

Thanks for the tip.

LJ

 

check your ground on the fan motor make sure it is tight a loose ground can cause the fan switch connector to over heat and melt. It can also cause the intermittent fan problems.

 

I didn't see a ground wire, just a 2 prong receptacle that the wire harness plugs into.

I replaced the blower motor - that was the problem.

After finding that I had voltage at the wire harness, I figured that it had to be the motor.

Here's how it went:

I bought a blower motor from Pep Boys for about $40.
They did not sell the fan cage, just the blower motor.
It did not have the receptacle for the plug on the motor - just 2 wires, so it looked like I was going to do some splicing. The motor did not come with the gasket, or the retainer ring for the fan cage.


I removed the battery, battery tray, and the AC accumulator (looks like a cannister of sorts) . I removed the 4 - 5/16 bolts from the fan motor - it came undone easy,
but I lost one of the screws down below where I could not get to. Be careful when undoing the blower motor screws.
The accumulator has 3 - 5/16 bolts on one side. You can use an eight inch extension and go through the hole on the battery tray mount to get to the bottom bolt of the accumulator bracket. It helps to use a swivel. After unbolting the accmulator, you have to pull it away from the fan motor. The accumulator is attached to the ac hoses so it has just enough give to get the blower motor and fan out.

After taking out the blower motor and fan, I could not take the fan cage off of the blower motor shaft.
In addition, the gasket was stuck on the blower motor mount, so I couldn't get it off without ripping it.
That was enought to make me decide to bring the new blower motor back to Pep Boys and go to the Ford Dealer and get the real Mcoy.

The Ford blower motor comes with a new gasket, retainer ring for the fan, and has the receptacle to plug the harness into.
It was about $110.
I had to buy the fan cage separately for about $20.
I think it's well worth it to spend the extra buck for the right parts (in this case).

Thanks for all the suggestions.

LJ