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Heater blower only works on highest switch position

Posted by zapp on Jan 10 2017 in HowTo, FAQ and Tech Hints

Not a classic car issue, but a problem I had on a newer Ford Focus: The heater blower does not work in switch position 1-3, only on position 4.

applies to

Brand

Ford

Model

Focus, Mondeo and more

Year

1998-2007

The solution is very simple. The blower has a pre-resistor that adjusts the rotation speed. If the resistor is burned or in other way broken, the blower only works at maximum speed.
To fix the problem, you need to replace the pre-resistor. But...the main reason why a resistor burns is a problem with the blower engine. To keep it fixed longer than a few days you should inspect and lubricate your blower.

The Ford Focus has the blower and resistor under the glovebox. All you can see is black plastic and some wire connectors. The first picture shows the installes pre-resistor. Simply unplug the wire and loose the screw at the lower end.

Heater blower only works on highest switch position
The installed pre-resistor in a Ford Focus II

In the next step you should remove the heater blower. Mine was attached by 3 screws. Newer ones have a bayonet mount. Don't forget to unplug the wire connector.

Heater blower only works on highest switch position
Old and new pre-resistor on the floor mat

After you removed the blower, you need to remove the blower cap. It is hold by 3 rubber noses (see red arrows in the picture below). Press all noses and carefuly pull the cap. Take care of the two wires between the connector in the cap and the engine. On my blower engine corrosion was visible at the axle of the engine (see green circle). I lubricated the axle endpoint with some WD40 and the unit turned smooth and without noise.

Heater blower only works on highest switch position
The heater blower engine with cap removed
This entry was posted by Zapp and filed under HowTo, FAQ and Tech Hints.

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