Looks like a million threads on here for climate fan motors that work partially or not at all. I've been reading about this for over a year & always see bits & pieces of advice, and never the whole story.
After my blower motor stopped working, and having no idea where to start, I replaced the 4 position switch ($25) and the resistor plate ($25). It worked for a few weeks, while I started losing speed positions again, then I was back to nothing. I replaced the blower motor ($28), started working again, then it completely died....
What I learned: REPLACE THE MOTOR FIRST!, along with the resistor plate, 4 position switch ***AND*** the plastic connector that plugs into the switch. Over time, your motor windings start shortng out, causing a heaver current draw, which ends-up pulling more ampergae through the switch, connector, wires and resistor plate - destroying all of it. The switch and connector both MELT from over-heating. I'm convinced this is why any problems occur on any of these.
All the parts are inexpensive, it's just a matter of doing it right. When you've only replaced the switch and/or the resistor plate AND NOT THE MOTOR, your motor can start working again, BUT you still have a motor that's on it's way out. Then you kill the new switch and possibly reistor plate, along w/ the plastic connector on that connects to the switch. (another $63)
I just went to NAPA to get another switch, and also the plastic connector. The wire connector is $63! (a $15 part at best) Knowing this is a weak link to begin with (becomes a gateway for poor conductivity) I realized the wires should be SOLDERED to the switch for best results. Just got through doing it, works perfectly. Solder your own set of wires to the connectors, then fill w/ hot melt. Now it's better than stock.
