2003-2006 Jeep TJ Blower Motor Resistor Replacement | This Old TJ

Today on This Old TJ: After replacing the HVAC controls did not take care of the two failed blower speeds, the blower motor resistor was the next part in line for replacement.
Short version:
See the chapters below if you're looking for something specific about this job.
Long version:
My resistor did not show any signs of over heating or melted wires. The newer model year Jeep TJ appears to be different from the earlier model Jeep TJ. Overall the process did not take very long to complete and requires minimum tools. The blower motor resistor I picked up was under $28 and came with a lifetime warranty. After replacement all fan speeds are once again working and there are no signs that the blower itself is failing.
Chapters:
00:00 - Intro
00:11 - Missing fan speeds
01:19 - Part number
01:32 - Total cost
01:38 - 2003-2006 Jeep TJ resistor location
01:58 - Remove the courtesy light
02:45 - Remove the wiring pigtail
05:28 - Closeup of the resistor with the wiring removed
06:05 - Remove the two 5/16 screws.
08:57 - Pulling the old resistor
09:26 - Comparing the old and new part, what's this number?
10:07 - Checking for an old seal
10:39 - Installing the new resistor
16:44 - Testing the fan speeds
17:16 - Reinstall the courtesy light
18:48 - Outro
Thanks for watching and please hit the like and subscribe if you'd like to see more videos like this.

[@chastings77]

Best video I came across detailing this, thank you sir!

[@thisoldtj]

Glad it was helpful and you're very welcome! I have three TJ's, all different years, to use making these videos now so more to come and things need repairing.

[@WhistlerSki2003]

Big time thanks. You saved me a lot of money and time. $29 for the resistor. Lots of corrosion on my 2006 LJ, the old resistor literally showed rust. Thanks to user-bq5kr9tl8s, when I couldn't get the wiring harness to budge, I pulled the assembly and luckily the old resistor allowed my to use pliers to get a grip on it with some WD40 to rock it in there with gravity helping. Finally free. Saved myself time next time by only tightening the bottom screw which was easy to access. I also pulled the screw from the wiring harness for more hand room (rusty one in your video). Of note, the red clip was easier to slide to the open position with a small screwdriver.

[@thisoldtj]

Glad to have helped! I now have three TJs in my driveway, ones a project, two are daily drivers, so more to come.

[@PaulJBaccash]

Thanks so much for this video! I had the same exact problem. I bought the part on Amazon and installed it and now all fan settings work! It was a real pain to get to it but I managed to get it done thanks to watching your video!

[@thisoldtj]

You're welcome! I'm glad it helped out. And it is a pain that requires a bit of patience to deal with. ;)

[@user-bq5kr9tl8s]

Thanks for the video! I had a hard time getting the clip off while in place so I removed the screws and took out the resistor pack first. Also, I had better luck pushing the red clip out from behind with a small screwdriver rather than trying to pull it out from the front.

[@thisoldtj]

Nice! Thanks for sharing what worked for you too.

[@michaelt6759]

Thanks for the video. I just fixed my friend's 2005 TJ by doing this. I also removed the neon green connector by undoing the christmas tree clips behind it, so I could get better access to the top bolt/screw

[@thisoldtj]

You're welcome, glad it helped!

[@sinnedam]

Thank you. Gotta do this myself as I have lost low.

[@thisoldtj]

Go for it! I think I spent more time setting up for filming than I did doing the actual work!