Once in a while and almost every morning now that it is colder out, the heater blower doesn't work at all (low, med. or high). If I unplug the resistor and plug it back in, it starts right up and blows on all speeds until I turn off the car and let it cool down again. Anyone experienced this?

 

i really think you answered your own question. The resistor is bad, replace that and you should be ok

 

I tried that unplug/plug trick again and no fan this time. the motor is supposed to work on high if the resistor goes bad... this doesn't work at all. I kept the relays inside over night and plugged them in when I started the car and still no fan. the next time it acts up, I'm going to see if there is a voltage at the motor leads. Is it possible the console controls are bad or whatever control board the fan speed button leads to?

 

yes i see your point that the resistor only varies the voltage for different speeds, without it would be straight 100% voltage to the fan motor which would give the highest speed. Definitely check to see if you have voltage at the power lead for the fan. It is possible that the HVAC controls have gone bad, but first check the voltage to the fan. We've had problems here with the blower fan before such as, bearings dying, making noise, lowered speed, things like that. I wouldn't be surprised if the fan was bad.

I posted up before here, have to do a search, but TYC makes an aftermarket replacement for about $40 instead of the $180 the dealer wants for this fan, if yours is bad. $180 for a fan is just plain ridiculous. so let's find out if there is voltage to the fan.

edit:
im looking at the service manual, what resistor? all i see is the blower motor control, doesn't look like it's able to be opened up. that would be the item you'd want to look at to see if the fan was getting voltage.

 

This speed control that people call the blower resistor is $150 so I hope it isn't that!! The motor is cheaper.
There appears to be this speed control with heatsink bolted into the air duct. Right from that is a blue wire that runs to the motor. I'm assuming there is a "power in" to this speed control, two "control wires" and that blue wire out to the motor. What baffles me is the fan motor runs through all of the speeds and sounds just like a motor should (when it is working).