A/C Resistor pack on a Windsor

[AttilaKara72]

I'm trying to locate the A/C Resistor pack on my 99 Windsor. I was told it was in the Jenny compartment on the passenger side. Well I can't find it. Does anyone have a picture of what it looks like? It would be greatly appreciated! My blower fan for my dash air only works on high, I'm told that the A/C Resistor pack is the problem. Or at least a place to start. Thanks in advance.

[BFlinn181]

The resistor pack is usually installed so the resistors are cooled by the moving air in the big black plenum, or box that contains heater core, A/C evaporator, and the fan. You can identify it by multiple wires attached to the resistor pack's connections.

[jacwjames]

I sent you a PM.

I took a picture of it, it is located on passenger side up high mounted on the box that surrounds the Evaporator pack. It is relatively small and has ~3 wires going to it. Mine has 2 larger red wires and a smaller blue wire going to it.

[CoCoDave]

Here's what it looks like stand alone.







The part number is D8BH-19A706-AB. Ford, if I remember correctly. You should be able to repair it with a thermal resistor. It's that small, cylindrical thing that sort of looks like a diode. It needs to be soldered in. It was the same set-up on our 2002 Diplomat and our 2003 Windsor and both of them had failed thermal resistors. So far, the Country Coach has not needed this repair.

These thermal fuses are so common that Radio Shack had three flavors in our local store. The direct replacement is rated at 262 degrees F, Radio Shack part number: 270-1322. Apparently these things commonly fail so it seemed that maybe they were spec'd on the low side. Given that, I elected to purchase the 288 F flavor (270-1320) which is about a 10% bump in temperature threshold. The really good news is that the price of one of these fuses is $1.69, plus tax.

I'm not sure how many Radio Shacks still stock that kind of part. Many of them are out of business or exist as a cell phone sales outlet.

FWIW

[bobcovey]

I bought a new module and it lasted 5 days, so I decided to replace the thermal fuse instead of paying another $28.

I may have bought the last Radioshack 120-1320 in the country a couple of weeks ago, and I could not find an equivalent part anywhere. If someone has an alternate part number and source please share it.

The original fuse is crimped into the bracket, not soldered. It took some finagling, but I was able to open the crimps with a hammer and punch using a small socket as an anvil.

Be sure that the springs and the fuse are spaced as far apart from each other as possible. I used RTV to seal it onto the plenum.

Cheers,

[CoCoDave]

Radio Shack still sells stuff online. Here's the link to the thermal resistor mentioned. They are also available on eBay, Mouser, Allied, and others.


Radio Shack Thermal Resistor

Mechanically crimped connections that are undone and redone will often times loosen later. That's why I like to solder connections like this. The 288*f temperature rating of the thermal resistor is well below the melting point of solder.

FWIW