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Old 08-15-2019, 04:18 PM   #1
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Dash HVAC fan switch only operates on high.

I've read multiple threads on this but still can't figure out it. On my 2002 Holiday Rambler Endeavor 38 the fan for the cab heater/ac will only run on high. Most threads say it is probably the resistor pack since the fan work but only on one speed. I tested the fan connector which has 4 prongs. One read 12V the others are read zero. I then tried to track down the resistor pack which from several threads appears to be in the from compartment attached to the plenum. Couldn't find it anywhere. I traced back the wires from the fan motor, and the wires off the switch.
The wires from the fan motor went through the firewall into the space behind the radio. They then were taped together with the wires from the switch and went back to through the firewall as a bundle into the front compartment. But I can't find where that one comes out. I've pulled away some of the spray insulation, but can't find it.
I also looked on the interior of the firewall to see if they may have put it there.

So I have questions. 1) should the fan switch connectors all have 12V BEFORE the resistor pack 2) is there some kind of a relay that I should check? I couldn't find anything like that, 3) what else could it be other than the resistors and 4) has anybody tracked down where the heck the resistor pack is located in an 2002 Endeavor. I'm stumped.
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Old 08-15-2019, 04:43 PM   #2
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Did you find and test the resistor pack? I'm not sure about your setup but commonly, the resistor pack is mounted into the air stream thru the hvac plenum wall. The resisters are cooled by the airflow of the hvac. The resistors provide resistance which slows the fan speed, until they burn thru and the fan no longer operates at that speed. Fan Hi Speed requires no resistor, so your situation sounds exactly like a burnt set of fan resistors. I will look at mine and get back to you.
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Old 08-15-2019, 04:49 PM   #3
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Here's two wiring schematics (same wiring but laid out differently).
Nice how Monaco like to tie different colored wires together....
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Old 08-16-2019, 07:08 AM   #4
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Country B,
Not exactly mine, but close enough, I'm stealing this, thanks!


BobWa,
You can see in the second schematic, if the resistor between 3 and 4 fails, none of the lower fan speeds will work. This resistor is in use whenever a fan speed other than Hi is selected, is most used and therefore, most likely to fail.
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Old 08-16-2019, 09:02 AM   #5
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Replace the switch and resistor pak. will fix the issue.

Ken
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Old 08-16-2019, 09:11 AM   #6
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"I tested the fan connector which has 4 prongs. One read 12V the others are read zero. I then tried to track down the resistor..."


It is my firm belief that the fan has two prongs, one positive and one negative. The resistor pack has four prongs. This belief is backed up by both of CountryB's schematics. Quite possibly, the four prong connector you found was connected to the resistor pack. Likely, there are two screws right next to where that was connected. Remove those two screws and lift out the resistor pack.
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Old 08-16-2019, 10:04 AM   #7
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Country B,
Not exactly mine, but close enough, I'm stealing this, thanks!


BobWa,
You can see in the second schematic, if the resistor between 3 and 4 fails, none of the lower fan speeds will work. This resistor is in use whenever a fan speed other than Hi is selected, is most used and therefore, most likely to fail.
I can't seem to find the resistor pack. I've looked everywhere I can get to. In the front compartment I can find the back of the plenum but there's nothing attached to it unless it's buried under foam insulation on the side. In the cabin, I can find all of the hoses that feed the various vents, but again nothing that resembles a resistor pack. What does the pack look like? And how many wires should be on it?
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Old 08-16-2019, 10:08 AM   #8
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"I tested the fan connector which has 4 prongs. One read 12V the others are read zero. I then tried to track down the resistor..."


It is my firm belief that the fan has two prongs, one positive and one negative. The resistor pack has four prongs. This belief is backed up by both of CountryB's schematics. Quite possibly, the four prong connector you found was connected to the resistor pack. Likely, there are two screws right next to where that was connected. Remove those two screws and lift out the resistor pack.
The fan motor itself has two wires, one brown, one white. As they leave the fan motor they go back through the firewall and into the cabin. Then a bunch of wires get bundled together including the 4 off the connection to the switch and a couple of others. I can't track those back anywhere. I've got to think that they go to the resistor pack but I just can't find the darn thing.
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Old 08-16-2019, 10:10 AM   #9
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Replace the switch and resistor pak. will fix the issue.

Ken
If I could actually find the darn resistor pack I'd replace it. It's hiding somewhere and I'm still trying to find it.
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Old 08-16-2019, 10:25 AM   #10
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See this website for an idea of what the Resistor looks like (note that you wil only see the terminals-end, the resistor (spring-like things) are usually in the plenum where the air flow helps keep them cool.

RED DOT | MOBILE SITE)
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Old 08-16-2019, 10:32 AM   #11
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Good morning Bobwa from down here in Auburn. Bob, the resistor pack on my 01 Windsor is located on the very back top of the plenum. All you will see, it's not that easy to see all the way up there on top, is a plug. The resistor pack is held in place by 2 small Phillip's sheet meatal screws. It is a Ford part. You might need a mechanics mirror to look up there. Also hope you are flexible as it is not that easy to reach. Have part number if you need it. Good luck!
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Old 08-16-2019, 10:50 AM   #12
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"I tested the fan connector which has 4 prongs. One read 12V the others are read zero. I then tried to track down the resistor..."
BTW, you would have 12V going "into" the fan switch (test by back probing the connector) but when you turn the Fan switch to different positions you should see the 12V on the other wires coming "out" of the switch. If none of the other wires have 12V (this is with the connector plugged in to switch) when you try all the different fan speeds, then the fan switch is bad.
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Old 08-16-2019, 11:21 AM   #13
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Good morning Bobwa from down here in Auburn. Bob, the resistor pack on my 01 Windsor is located on the very back top of the plenum. All you will see, it's not that easy to see all the way up there on top, is a plug. The resistor pack is held in place by 2 small Phillip's sheet meatal screws. It is a Ford part. You might need a mechanics mirror to look up there. Also hope you are flexible as it is not that easy to reach. Have part number if you need it. Good luck!
Thanks 8.3, I'm not that flexible anymore but I'm determined to figure this out. I'll probably remove the front compartment cover since it's even harder working around that. I'll let you know what I find and get back to you about the part number.
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Old 08-16-2019, 11:24 AM   #14
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BTW, you would have 12V going "into" the fan switch (test by back probing the connector) but when you turn the Fan switch to different positions you should see the 12V on the other wires coming "out" of the switch. If none of the other wires have 12V (this is with the connector plugged in to switch) when you try all the different fan speeds, then the fan switch is bad.
Thanks CountryB. I'll check that today. So with the ignition turned on I should see 12V coming out of all of the wires which then get reduced at the resistor. If nothing is coming out of the others than the switch isn't feeding power to the resistors and the switch is bad.
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