1993 Legacy HVAC blower resister assembly
Posted: Fri Jun 25, 2021 6:13 am
Don't throw out your old one, or original Subaru version. They are though a unit that is designed to fail. There is a terminal that has what is like a metal strip conductor similar to a flat spring that is soldered to it. Two stupid things they did. 1st is using solder, 2nd is the side of the terminal the strip is soldered to the terminal, when the solder melts the spring pulls away and then you only can use high speed on the control switch.
And maybe yeah they are making it act like a fuse, but then all those resistor coils are designed to get hot. And an after market motor could load differently as well or build up of trash can restrict the cooling air to the resistor assy. Anyway my fix for it is to bend the top side (as installed) open and use small needle nose pliers and move that springy, conductor to the other side of the terminal, then I took a cut out tin can lid from a can of beans, and cut a small strip about 3/16 or maybe a bit less wide and bent it in the middle, then snipped off and left it may 3/16 long from the folded end and then pinched it over those terminals to hold them together. Folded the little flaps back over. Seems to work okay now.
And maybe yeah they are making it act like a fuse, but then all those resistor coils are designed to get hot. And an after market motor could load differently as well or build up of trash can restrict the cooling air to the resistor assy. Anyway my fix for it is to bend the top side (as installed) open and use small needle nose pliers and move that springy, conductor to the other side of the terminal, then I took a cut out tin can lid from a can of beans, and cut a small strip about 3/16 or maybe a bit less wide and bent it in the middle, then snipped off and left it may 3/16 long from the folded end and then pinched it over those terminals to hold them together. Folded the little flaps back over. Seems to work okay now.