Dash blower rebuild with (cheap) Jeep resistor - w/PICS

[[email protected]]

Thanks, just did this very easy and now I have all 3 speeds. Quick question how are people sound proofing the front? I have some stick on sound blocker, just wondering were the bast placement would be.

[djkeev]

I think that a heat shield around the radiator Is far more important than sound deadener.
The heat that comes off that radiator channel is a KILLER in the Summer!

Dave
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Stop Dead Photo Links how to post photos

Ghia
http://www.thesamba.com/vw/forum/viewtopic.php?t=392473

Vanagon
http://www.thesamba.com/vw/forum/viewtopic.php?p=6315537#6315537

Beetle
https://www.thesamba.com/vw/forum/viewtopic.php?t=482968&highlight=74+super+vert

[joshtw709]

I just did this conversion and notice melting plastic smell every time I have the blower motor in setting one or two, but never in setting three (didn't convert to the four speed fan switch). I can cruise it in setting three and then go down to setting two and notice melting plastic smell in about 20 seconds, kick it back to setting three and it goes away. any idea what is going on here? I've replaced my blower motor, wiring, and resistor. I have a new switch in the mail but I have a hard time thinking it is the cause.

cheers,
josh
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1980 rusty light blue westfalia - sold
1987 less rusty white westfalia - daily driver

[IdahoDoug]

I did this mod n have no smell.
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1987 2WD Wolfsburg Vanagon Weekender "Mango", two fully locked 80 Series LandCruisers. 2017 Subaru Outback boxer. 1990 Audi 90 Quattro 20V with rear locking differential, 1990 burgundy parts Vanagon. 1984 Porsche 944, 1988 Toyota Supra 5 speed targa, 2002 BMW 325iX, 1982 Toyota Sunrader

[danfromsyr]

the coils on the resister get HOT. did you get any plastic shavings on them when installing them into the hole? or is it too close to an edge or the back inside.

the fan airflow is supposed to help in cooling the resistor coils. perhaps it's not getting enough of the airflow.
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[joshtw709]

the smell seems to lessen when I have the floor vent closed and all the air coming thru the dash vents. presumably greater air-flow across the resistor is occurring when I close off the floor vent?
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1980 rusty light blue westfalia - sold
1987 less rusty white westfalia - daily driver

[djkeev]

I too did this mod with stellar results.

My guess is debris on the elements or a very bad location of the resistor.

When working, the coils glow red hot like a toaster. If it is located poorly without cooling airflow, plastic nearby could indeed melt.

Dave
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Stop Dead Photo Links how to post photos

Ghia
http://www.thesamba.com/vw/forum/viewtopic.php?t=392473

Vanagon
http://www.thesamba.com/vw/forum/viewtopic.php?p=6315537#6315537

Beetle
https://www.thesamba.com/vw/forum/viewtopic.php?t=482968&highlight=74+super+vert

[dhaavers]

Very reasonable explanations above. Unless your heater box is somehow damaged, plugged
or otherwise modded, there should be plenty of airflow to cool the new resistor.

Post a pic of your install...could be a great help in our long-distance troubleshooting...???

- Dave
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86 White Wolfsburg Westy Weekender
"The WonderVan"
<EDITED TO PROTECT INNOCENT PIXELS>

[joshtw709]

[Paulbeard]

Just to post an update. Looks like mine failed after 2 1/2 years. Three speed switch (OG) and the middle speed isn't working, as tested with a wire jumper between the switch terminals. So off to replace the resistor. Maybe I'll find a more durable one this time.

EDIT: looks like the part number at Oreilly (my FLAPS) is 2BMR15 from MPI. I ordered the wrong one from the big online superstore which I now have to return. Yes, I could cut and splice the wires to make it work but the point of this to be a simple R&R.
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Currently -> Frida: 87 Tizian Red (mostly) Vanagon GL Westfalia w/ 2.0L ABA conversion
Formerly -> Steward of a 73 Super Beetle (Beater) and 67 Beetle 1300 (Little Max) both names by POs

[Zeitgeist 13]

The info I learned in this thread helped me to resolve an issue on a completely unrelated vehicle. I'm servicing a friend's '82 F150 (eyeroll) and was having a hard time locating the correct fan resistor--for reasons unknown, this truck is kind of a unicorn for lots of parts. None of the resistors I found from the usual sources were the same, but then I remembered this thread and began looking for a Jeep unit. Sure enough, the '92 Wrangler used a slightly smaller unit, but even the spades fit the Ford plug. With some small mods I was able to get it to fit, and it was less than $7
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Casey--

'89 Bluestar ALH w/12mm Waldo pump, PP764 and GT2052
'01 Weekender --> full camper
y u rune klassik?

[dhaavers]

The resistors never last...at least you could get to it easily!



- Dave
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86 White Wolfsburg Westy Weekender
"The WonderVan"
<EDITED TO PROTECT INNOCENT PIXELS>

[dhaavers]

FWIW...Related recent discussion: https://www.thesamba.com/vw/forum/viewtopic.php?t=694838
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86 White Wolfsburg Westy Weekender
"The WonderVan"
<EDITED TO PROTECT INNOCENT PIXELS>

[luVWagn]

Who has ordered one of these lately AND had it come with the plastic connector/harness for the resistor?

Not sure if this one comes with a connector or not:
https://www.oreillyauto.com/detail/b/masterpro-ign...15/4506749

Thanks!
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'91 Syncro 16 Reimo Hightop Conversion, eTDI

[Paulbeard]

[dhaavers]

Several vendors on eBay supply Dorman brand w/harness: https://www.ebay.com/itm/Blower-Motor-Resistor-Kit...1438.l2649

FWIW: I'm still running my OE Mopar brand resistor w/no troubles...

- Dave
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86 White Wolfsburg Westy Weekender
"The WonderVan"
<EDITED TO PROTECT INNOCENT PIXELS>

[markswagen]

i recently put one into westy that i converted from air-cooled, i'd already previously fitted the BMW brake booster to the van, and space looked very tight in there, so i fitted the jeep resistor on the other side of the heater box, if it were to require replacing, it's now accessible from the glove box, I rewired it all anyway, so the new wiring was made long enough to go around the back of the heater box, it's all good.
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markswagen {mobile mechanic} san diego area all early VW's cared for.

619 201 0310

[DuncanS]

Sure glad to have found this thread. Even with a lube tube for the left side bearing, my fan now growls so loudly, the Bach Cantata and Fugue in D minor for the organ at full blast is not appreciating the competing fan "duet". The PO kindly delivered my '91 to me with a frozen fan which I was able to free, but.............

However, I always assumed the huge ceramic resistor behind the left headlight was the fan speed controller. Apparently not as nobody mentioned such an item. What is that one and what does it do? When a few of my older T3's died, I "harvested" these just in case and so have two spares.

I have used the bearing lube tube for the last 4 T3's I've had and it makes a huge difference. Dash coming out this summer and will do all of what you have done, but worried about all the various failures mention in the posts. Maybe the resistor loads are just too high for the switch contacts and relays should be used. I noticed that no one followed up on nocreditnodebt's old post copied here below.


For those who don't mind a little modification or a Non stock appearance, A PWM motor speed controller rated to handle the amperage can be used to control blower motor speeds, and instead of set speeds, infinitely variable.

https://www.amazon.com/uniquegoods-Controller-Adjustable-Variable-Switch/dp/B00K4W4FQO

Motors might emit a whine when slowed though vie Pulse width modulation. The higher the HZ the better with speeds over 16khz likely inaudible to humans.

Some versions allow one to change the frequency too but I lost the bookmarks.

I recently did a new blower motor and resistor and resistor connector in a Non VW application, and kind of regret not going the PWM route instead.

I upgraded wiring to 8awg and the motor gets so much more voltage and spins so much faster, it moves as much air on medium high speed as it did on high previously.

Me again--Why not use this and skip all the switch and resistor and possible melting plastic issues altogether? His post was 2015, so I assume that by now the electronics are better and cheaper.

Duncan

[dhaavers]

Granted, The OG dash switch IS prone to failure, but easy to change out. Likewise, the Jeep resistor
mod is not a permanent fix (no resistor lasts forever) but definitely an improvement because it is
much easier to change out than the OG resistor buried deep inside the box buried behind the dash.

FWIW: Resistor behind headlight = radiator fan, controlled by radiator temp switch (...& associated relay...???)

PS: My OE Jeep resistor still holding up 4 years on, but always interested to hear about other effective options....



- Dave
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86 White Wolfsburg Westy Weekender
"The WonderVan"
<EDITED TO PROTECT INNOCENT PIXELS>

[corypharmd]

Hey @dhaavers, did you wire it with 1 being low, 2 being medium, 3 being high and 4 being the clutch? Thanks Cory
1986 Syncro full camper
1983 westy camper