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I have had problems with my 1998 Ranger vent/AC blower. I have replaced my resistor, that worked for only a couple weeks and then it went back to only working on medium high and Hi. My next guess would be to just replace the blower motor? One other thing, my wiring harness that connected to the resistor was melted on to the resistor so i cut the ends of the wires off and put plugs on the end of each wire and wired it directly to the resistor. I don't feel that is a problem, but someone who knows more can tell me other wise. I did that because i could not find that pig tail anywhere. thanks for the help.
Can you get access to a ammeter? You could then do an actual measurement of the blower current draw. You can take the motor apart and inspect the brushes. Generally, when they wear out, you will get intermittent operation. The only two reasons, off the top of my head, for excessive current draw are bad bearings and shorted armature windings. I think worn brushes would cut the current flow. If you have a bad ground to the blower motor case, that could cause problems too. Measure the voltage to ground at the connector to insure you have a good connection.
tom
Blower motor change out no doubt, my 99' with 305,500 miles on it and it started on 3-speeds then went to 2-speeds then HIGH only and then would work every now and then. Changed the blower motor (junk yard $30) and all was ok even took back the switch because I thought it was the problem.
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