DuB-EnG: Fan Heater Speed Control repair on Wolkswagen T5 T6 - Resistor matrix repair / replacment

Your fan heater only works on setting 4 (maximum) and the lower speed settings 1, 2 and 3 do nothing. Here is a video on how to replace the wire-wouund speed control resistor matrix and an investigation on how it works and what the cause of the failure is.

[@AdamWelchUK]

I replaced the thermal fuse on a resistor pack a good 15 years ago on an old focus. I bought a handful of the fuses (from maplin I seem to remember) with the same thought - soldering would pop them. The first one soldered in fine. I imagine they need a few minutes at their rating before they blow. Sold that car with that repaired resistor pack a couple of years later. They sit in the air duct to help keep them cool. I guess the air can be moist in there sometimes which explains the slight corrosion.

[@DubiousEngineering]

Maplin.. we're they better than tandy?

[@ruinunes8251]

I feel your pain regarding those resistors. I changed a few resistors in my civics over the years. At some point I was able to buy the coils and solder them in place.

[@DubiousEngineering]

I may have a go at repairing this in the future myself - I'll likely use a slightly higher rated thermal fuse! :-)

[@ruinunes8251]

@@DubiousEngineering if you can find the parts, why not? However, using a higher rated Termal fuse, not sure about that

[@stevehughes7450]

Thanks for taking the trouble to post this - most helpful. £15 new part online (loads of choice) and job takes about 20 mins on a T6 (harder on a T5) Access is tight and only one screw can be removed with a 5.5mm socket on a 1/4" drive ratchet. Get yourselves a 5BA open ended spanner which fits the hex perfectly and is much easier (I don't think you can buy a 5.5mm open ended spanner readily but 5BA can be found online

[@DubiousEngineering]

Great tip Steve, yes an open ended spanner is well worth investing in!

[@JackBealeGuitar]

Nice repair job, good to see you back again. Fancy coaster you had your meter on too, very exclusive looking

[@DubiousEngineering]

Very Skype arms

[@Mymatevince]

Nicely explained Howard. I recognised that thermal fuse from a coffee machine that I previously looked at, AND yes I did blow the first fuse from from soldering it in place 🤣 Great video and I hope you are keeping well 👍

[@DubiousEngineering]

Immediate and rather mahoosive thumbs 👍 up to the amazing 👏 My Mate Vince for taking time out to actually watch one of my efforts... genuinely hope you are also doing great mate!! 👍 can we have a beer one day :-) teehee

[@Mymatevince]

@@DubiousEngineering Most definitely Howard 🍻🍺

[@karen4you]

If that could be modified with a snap in fuse it sure would be handy. Hope whatever issues are ironed out whatever they might be. Down time is always needed. A healthy new year to you and all in your family.

[@genghisbunny]

That's a good idea - maybe one could use an inline fuse holder? That way you just solder in the wires and then change the fuse as required...

[@DubiousEngineering]

Happy new year Karen and Bunny 🐰!! ... both have great ideas!!

[@Paxfoxus]

Happy New Year to you all… looking forward to 2022 projects

[@DubiousEngineering]

Massive happy new year Simon!

[@timballam3675]

Wondered where you had been, have a good new year..

[@DubiousEngineering]

Hugs Tim... been a bit poo here recently but we're getting back up to speed slowly!!!

[@genghisbunny]

Great video, happy new year mate! This was really interesting. Did you consider using a battery spot welder to replace the fuse? It would be fiddly for sure... Just a thought for future. Thanks as always for sharing the repair journey, not just the solution.

[@DubiousEngineering]

I may have to make one of those spot welders... I keep thinking ill need one!

[@genghisbunny]

@@DubiousEngineering I got a battery powered one that charges over USB for like $50 on Ali Express, it's really good. Was going to make one but saw a review of these and they seemed worth a try, and I'm glad I did.

[@tropicalscuba]

I've replaced mine twice now (learnt from your guide of course). The third one is in place and again, chemically smells coming from vents, unless it's on 4, so i think this is going to blow too. Any thoughts why it's getting stressed and burning out each time? (12 plate T5.1 140bhp T32)

[@DubiousEngineering]

That is so annoying!! I've done mine once and keep wondering when it's going to happen again!

[@mm-hq4qh]

I have a problem with back/roof ac,webasto in the back works but it dosent blow air. Any help?

[@DubiousEngineering]

You need to check fuses and then get the multimeter on the switches to test for voltage

[@lauriruusila4405]

My T5 is alwats blowing on 4. Blower will only turn off when you shut the whole car down. Any ideas whats wrong?

[@DubiousEngineering]

Sounds like the switch on dashboard is faulty

[@traceybarton-williams3038]

Is it the same repair if my fan works on 1 & 4 only?

[@DubiousEngineering]

Yes

[@tombreeze6148]

Can the fuse not be Crimped in place? like a portable heater

[@DubiousEngineering]

Great idea... I'll do that to the spare!

[@Everythings_Adjustable]

I got nothing clever to say so have a good one Mate 🥃 👍 😊

[@robertcrawford2287]

Literally just happened on my t6. Do you have a link for the one you got to replace?

[@DubiousEngineering]

Son of a ... they are available on ebay and amazon

[@lynnetyson9151]

Me too. 4 year old T6

[@leeg4116]

Is that a common thing for those to go on a van that young? You could have at least cut the old one open and let us have a look inside lol. Also, a ratchet spanner would have been ideal for those small bolts mate

[@DubiousEngineering]

5.5mm bolts... blooming nightmare!!

[@patrickstarnes2355]

I've got an old suzuki jeep, the ventilater works but I can't change direction of air flow.🤔 Probably a similar faulty thingemegig😃🤣😂

[@DubiousEngineering]

Sounds exactly like a poo 💩 thingymajig ...

[@s-om6962]

My fan speeds are ok..the problem is the temperature regulation. it is either at 26degrees or stone cold..would this part fix that as well ?

[@DubiousEngineering]

Nope…. Sorry…. That’s a totally different issue

[@jamiejobe7456]

@@DubiousEngineeringhey mate, I have a 2005 T5, I need this part to fix my fan speed issue. Would you happen to have the part number I need for my T5? Thank you in advance Jamie