2004 AC blowing intermittently | Ford Thunderbird forum club group 1955-2005 models
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2004 AC blowing intermittently

paulH

paulH

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Thunderbird Year
2004
My AC is blowing intermittently on Auto.
From what I can find in the internet it is probably a bad blower resistor.
Cheap part but very difficult to change it seems.
Any suggestions or advise?

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I did this repair, replacing the heater/AC blower resistor, a couple of months ago. I had watched Tbird Bob's video but didn't like the idea of cutting the housing to get access. Then another fellow wrote that his shop did the replacement without cutting. I followed that advice and loosened the main heater/ac housing by removing the nuts on the box's mounting studs (on the engine side of the firewall) and that gave me just barely enough room to extract and replace the resistor. The whole job was tedious, requires removal of the glove box and the cabin filter housing in the engine compartment and lots of hours on your back on the passenger floorboards removing heater/ac related housing screws etc.
 
Hi Allyn, thanks a lot for providing an alternative without cutting and removing the cpl dash. Any pictures available on how you did it. Thanks. Paul.
 
Hi Paul, I did not take pictures of the repair process. I was just experimenting based on the report that someone else did it without cutting the housing and having to do some sort of repair to that as well as replacing the resistor. If you haven't seen the resistor yet it is large! That is part of the problem gaining enough room to get it out. but I think loosening the main heater housing gives you just enough room to pry things apart where the resistor can be withdrawn. It's not a job for the faint at heart, but when you have the blower out of the housing it is easier to see where just a little more looseness in the housings that make up the heater and AC system give you just enough room to remove the resistor and install the new one. By the way, my 2003 was doing multiple crazy heater/ac things. Couldn't shut it off without turning off the engine and opening the door, couldn't adjust the blower speed or temperature correctly. Also, I read that you should replace the valve in the coolant system that controls the driver /passenger temperature settings as a faulty valve assembly can damage the electronics. Not positive that this occurs but it isn't very expensive and is available. Hope this helps.
 
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