Chevy Astro: Blower Resistor diagnose/replace

[@rogerschultz7666]

I know this is an older video. But just wanted to say thanks! When I went to purchase a new resister for my 1998 Astro. And tried to install the replacement. I ended up taking it back. After discovering that all the replacements were of the same nature. I didn't know what I was going to do. Even O.E.M. resisters were the new design. Watching your video was priceless. I went back and repurchased the part. Did the revisions you described. And Viola! It went in perfectly. Great video!!

[@Gregasaki]

Thanks. Great video. This part and the vacuum lines go out on all these vehicles. There’s a fuse under the driver dash and fuse under the hood in the relay box, or two if you have rear heat. Of note: the high setting contacts and the contacts for the big orange power wire often need scraped and coated in dielectric grease. And lemme say this: the low medium settings will still work even if the fuse in the relay box has blown. Like everything in these vans it’s patient job. Thanks

[@veggiepowered]

This Video Helped Me Get My 1999 Astro Van Blower Motor Working In All The Speeds again. I Had To Cut Those $ Tabs Off Too Thanks For Posting This Video It Helped Me. I Went To That Happy Valley Chick-Fil-A Grand Opening And Camped Out For Free Food For A Year Many Years Ago

[@BrotherDonald]

Thank you. I never would have been able to find where they had hidden that blower resistor without your help.

[@3v1ld34d]

i just did the same repair on a 2001 astro. i got the resistor at a local u pull for 3 bucks. thank god i cut the harness/connector from the donar van. not only was my resistor fried but my harness/connector high side was melted as well. after replacing the resistor and splicing,soldering,and shrink wrapping the new plug my air was back. cheers

[@PineHollowAutoDiagnostics]

Win!

[@DoItWithDave]

Hey just wanted to thank you for publishing this video. REMEMBER TO CHECK BOTH FUSE BOXES don't be like me.. My 2000 Astro resistor burnt out so I replaced it. I did the light test but only got the (Always Hot) thick orange wire to test hot. So instead of using the "the simplest solution is normally the best solution" I decided to track wires back to the fuse box under hood. Removed grill, bumper nose, cooling fan splash guard to find no chafed wire.....I did fine just behind the battery a thin rectangular junction where the thick orange wire ran. I disconnected and found the harness has signs of burns and I m not sure why that is. When I wiggled that connection while testing the orange wire on the resistor side, the light tool would go on and off so I can only assume that junction is a contributing factor to this common issue. Any way finally was about to throw in the towel and looked online for fuse box locations. I didn't realize there is one under the driver side kicker panel. Wouldn't you know the 20amp ac fuse was blown. Replaced it and got all 4 terminals to light up using your method. I felt pretty green on this one. Thanks again. Ft.Lauderdale Fla

[@PineHollowAutoDiagnostics]

Glad you got it figured out! Did you use a wiring diagram? That will point you in the right direction right away :)

[@patriciaheald9927]

Want to thank you for your video on the Blower Motor Resistor Replacement. It was a life saver as I had the same problem as you in that the new one didn't fit. Thanks again.

[@DoctorDification]

You are the only person out here with the fix on this, thank you

[@Jes_Glaze]

Thanks. Perfect solution to my problem. AC would only work on high and changing the resistor did the trick

[@DesertEagle713]

Awesome video! I did the same repair a while ago and tried an aftermarket resistor and they actually had instructions that said to cut the air box to make it fit smh... I ended up getting the Acdelco and cutting the plastic tabs on it... worked great.

[@asavag3]

I cut the tabs too. Easy peasy

[@CommonSenseTipsAndTricks]

Thanks for making this look so easy! I might try this because my blower fails to run on high speed. But the ac max works still at a lower speed than before though. Like the old regular high speed. Good information!

[@dkevvv]

Thanks for the video. Even years later it is helping. SO,,,,, I removed the resistor and the duct behind it was full of leaves and pine needles. How the H can this stuff get behind there?

[@frontierlife552]

Great video. That helps me a lot. I have #4 speed not functioning. I’ll trace that one back and see if it has power. Mines a 2004 so it should be the same

[@Superduty_59]

Thanks for your help. I have had some issues with my company vehicles over the years. My work buys 3500 Chevy and GMC vans for us. My last 3 vans have had issues. The 3rd to last had 2 resistors replaced and 1 blower motor, my 2nd to last van had 2 blower motors replaced. my current van has had the dash controls replaced and the a month later the resistor seems to be bad. Well that didn't work. I just replaced the resistor and same thing.

[@Briansmusic-]

Nice I just did the same thing before watching this with the plastic and bending the tabs. Mine needs a blower motor though. Its still coming on 5 minutes after I turn it on. Anyway great video and thanks.

[@binnsh]

Just did this on a bud's full size GM van. The instructions mentioned cutting the opening using a template (of course missing from the package). Looks like I should get an amp clamp.

[@michaelbohlier7608]

Your video was very helpful to me in repairing my Astro. Especially the resistor pack modification.

[@PineHollowAutoDiagnostics]

Cool, hopefully it lasts you a long time!

[@mgbgtguy]

Just doing this myself and found no matter what brand resister pack you buy they are exactly the same. They are all just like the one you got. which is the one for earlier vans, There was a change somewhere around 2002, but they provide the same replacement part for all.

[@kevinschanuel5292]

I own a 2002 GMC Safari. My blower motor doesn't work on any speed, when turning on. When hitting a hard bump the right way, the motor kicks on. I pulled the coolant overfill and the windshield wiper fluid tank and checked the resistor harness, the connectors were clean. I hooked it back up and tried wiggling the harness in which the blower still did not turn on. I taped the top of the plastic cover (DELPHI) that's above the resistor and the motor started. What is the problem and what is in the black container that might be shorting?

[@startingtech3900]

MINE DOES THE EXACT SAME THING. WHEN HITTIN A BUMP. what was your issue kevin???

[@leighvold2548]

I really wish you would have shown how you bolted it in after cutting the bolt holes off of it. thank you.

[@racrx7]

Glad to see there are still good trouble shooters out there! Well done. Now let me go fix mine lol

[@ACharbonneau911]

Thank you for your Talents

[@JosephCompnotta]

Thanks! I have a 03' as well I parked my Van for 6 days and got in and had no fan power on all the speeds. Worked fine prior to parking. Any ideas?

[@schizophrenicdolphinz9822]

fuese maybe?

[@JetSettingBotanist]

My blower works on all settings but high? Could this still be the resistor? I’ve had a bad blower motor for a few years now where I have to hit it sometimes to get it to work, that would explain burning out the resistor right?

[@MultiPablo1987]

Hello. I hope you can help me. The blower motor is working the blower motor resistor is working, but I did the same test you did for the cables and the only one that the lights come on is the black one and I checked the relay and the fuse are good. What else can be.?

[@MultiPablo1987]

I forgot to mention that the problem I have is no air coming in any of the vents . Thanks.

[@theeliterumbero]

Thank you so much for the video! 😁 I'm going to pay it forward.

[@tank2402]

How much are we able to cut. The resistor doesn't come close to fitting. I would have to cut away much of the plastic where the larger block on the resistor is to fit

[@daddyosink4413]

My Mom's 03 Safari has nothing blowing in the front or back.... is there another resistor for the back system, or does this one do both?

[@hmhardwoodflooringllc4208]

Hey my chevy express 1500 only find electric power on red wire, do you know what's wrong?

[@SteveRobReviews]

Just loved them vans, drove one for 10 years never replaced the resistor though. Ivan did you notice the new resistor was built in Slovenia , Japanese or Korean manufactures generally don't use a European supplier, I think it great that Gm and Ford will. Was there not a notice in the box outlining a design change to the housing to alter ? The people in the Baltimore plant did a great job with the van I knew quite a few of them , sad day when it closed down. Very thorough testing Ivan. 👍

[@PineHollowAutoDiagnostics]

Steve Rob Hah yeah I did look at the instructions after the fact...and yes they had some templates to widen the existing hole in the air box :) I think my "modification" worked out pretty slick too lol

[@luiscasiquezuniga3054]

My connector does not receive a positive signal and a ground signal reaches each cable. Could the problem be the controls?

[@xraykadiddlehopper8067]

So much for your OEM theory. Dorman products are much cheaper and equally sturdy. If your smart you never buy from the stealership unless theres no other option.

[@PineHollowAutoDiagnostics]

or if you don't like comebacks haha

[@light0000]

Help! Not only does my fan operate the same way! But sumtimes not at all. And i have to hit my dash above or directly on the control knobs to make the one speed kick on...

[@ThenZ6]

And when none of the speeds work? I have to find a schematic and trace voltage for that I guess. Hoping I can just replace the whole thing and it’s good

[@scottymizzo415]

thanks for the info on how to check the plug for power

[@Jack-Surreal_Panes]

off the topic but I see a small black plastic vacuum line while you were doing the final voltage check. Where does that connect to. I replaced my other lines, rotted, and have this last line that is currently taped up but have vent air and heat. No AC yet but baby steps. It has to plug into some p.ace over there, maybe the 4 outlet front heat thing. It is the other line that comes thru the firewall. looking thru Tube videos and pics to see where this goes to.

[@PineHollowAutoDiagnostics]

Vacuum reservoir?

[@Jack-Surreal_Panes]

+motoYam82 the engine block to the 3 way. 1 goes thru firewall other goes to the resevoir. there is a long one coming out of firewall, not on the 3 way, and guessing there is another valve or switch this hooks up to that is mounted left and behind the resivoir bottles and the evap. may have something to do with ac too. it doesnt even crank on. I taped it up and now the fan works and blows air from the vents. Have heat now

[@whitetiger8652]

Great work Ivan.

[@clarktferrill]

I have also checked the 30a fuse under hood in box with relays etc...

[@stuzman52]

Nice work and diagnostics Ivan. You would think that when designers make a change, their first goal is to make it fit as it did before. And hopefully, the electronic design is better than it was before. I've seen dozens of revisions for industrial components such as PLCs which makes you think they couldn't get it right after all those times. As a side note, I had subscribed to you from your earlier video, but I guess the KZbin programmers have been working again because you weren't listed in my subscriptions. Steve Rob helped me in locating your channel. Take care Ivan.

[@PineHollowAutoDiagnostics]

stuzman52 Thanks Terry! Yeah looks like they decided to use discrete resistors in the updated version instead of printing them on a thin circuit board...Failure rate was probably too high on the original design :)

[@PineHollowAutoDiagnostics]

motoYam82 BTW still don't see you in my subscriber's list?

[@stuzman52]

motoYam82 The exact same thing happened to me after I had subscribed not showing you in the subscription list. When I went to your channel, it showed that I was unscribed. I clicked on the subscribe button again, and then you showed up in my subscription list. KZbin must be doing some programming again giving us these quirks.

[@VashthStampeede]

+motoYam82 I had a blower motor's bushing go dry and the motor would not come on for the first two low speeds and screamed on the two higher speeds on my 2000 S10. I replaced the motor with an aftermarket motor and the two low speeds did not work. The blower motor resistor burned out because of no airflow at low speeds with the old motor. I replaced the resistor and all worked fine, except the new motor had a whine I could not live with. I finally regreased the bushing on the old blower motor and reinstalled it. All is good now. After seeing that the blower motor in your video would not come on when started at the lower speeds tells me it is old and tired and could possibly have caused the resistor burnout if the driver had not realized it was not functioning.

[@ourgrassisblue2153]

My blower motor resistor is making a humming noise whenever it’s plugged in. I’ve tried two different new ones and it still is making the humming noise and does not blow

[@Spectt84]

I need some insight. I've had a lot of problems with my 2003 Astro van blower. I've replaced my resistor, the blower motor itself (because it was old and drawing too much power causing the resistor to keep blowing), and spliced in a new connector going to the resistor. My problem is the "high" setting. I am getting no power at the thick orange wire at the connector going into the resistor. I'm not sure what to check next...

[@kellymerriman4591]

Did u ever figure out the no power to fat orange wire.. cause I have the same problem on my 2002 chevrolet astro.

[@kellymerriman4591]

So I replaced my resistor and blower motor and climate control switch(used climate control) a couple months ago and had all the temps but high.. then It all stopped working and the fat orange wire that's suppose to be hot all the time wasnt.. so I spliced into my orange wire just after the wiring harness and also under the 30 amp fuse under the hood and connected them with a new 12 gauge wire and now I have high heat! But none of the others.. I'm guessing my resistor went out cause of that bad wire n will be replacing that later so hope hopefully I'll have all my settings working

[@rodrodriguez1365]

I've been having a similar problem but what I want to know is what is the D C104 on the schematic diagram you show on the continuous current flow mine doesn't work.

[@kellymerriman4591]

My thick orange wire in my resistor wiring harness is not hot either .. did u ever figure this out?

[@daddyosink4413]

My Dad took his van to a local AC shop, they have had the the van for over a week and charging him through the nose because they say that resistor is under the dash and they have to remove the entire steering column to get to it. And people wonder why I do all of my work myself.

[@PineHollowAutoDiagnostics]

Wow sadly happens too often, especially at dealerships!

[@daddyosink4413]

@@PineHollowAutoDiagnostics this guy owes my Dad money, so hes just running the bill up. I personally wouldnt let this clown touch a vehicle of mine.... he put power steering fluid in the brake system a few years ago, you already know how that turned out.

[@kellymerriman4591]

What does it mean when that fat orange wire that is suppose to be hot all the time is not? I took a test light to it and it does not light up?

[@kellymerriman4591]

So I spliced Into the orange wire at the wiring harness and under the 30 amp fuse under the hood and now I have high heat!

[@JamesAgans]

It amazes me that these circuits depend on such miniscule amounts of current flow. No wonder they are so problematic. I guess this is because auto systems run on only 12 volts? It does not take much to foil 12 volts, and I understand that the computer reference voltage is only 5 volts, right?

[@jtech23]

Don't see many of those on the road any more around here. That resistor was toasted pretty good wasn't it. Lol.

[@PineHollowAutoDiagnostics]

Jonathan Milbury French toast.

[@hectoraymo9963]

Thank you very much☺👍

[@DoctorDification]

I cannot find that part !!!! Help. The replacement everyone specs looks nothing like what come outs and I can't get that thing in either

[@qtip919]

does anyone know what size of bolts hold that part in?

[@matthewblevins2584]

Thanks getting ready to attack same issue on my 01

[@LZDEN]

theres always the banana skin to slip on Ivan...as proved when the new part didnt fit...;-)

[@produceconstruction9228]

Good job AAA+

[@Lilmiket1000]

oh just about gave me a heart attack. I was like NOO dont cut the air box. Cut the tabs off the part lol.

[@Gottahandle]

I pushed defrost button an wisp of smoke came out I shut it off right away I replaced a couple fuses thinking that would be I started it an same thing I shut it off . But it wouldn't start again. It's shorting somewhere. But where I'm no good art none of this .

[@OldSchoolNoe]

Good!

[@devinriver901]

I wish you would have shown removing the blower resistor, would have been helpful for someone who's not done this before.

[@PineHollowAutoDiagnostics]

+Christine Anderson Ah sorry about that...I think the replacement resistors come with some basic installation instructions :)

[@devinriver901]

+motoYam82 ok thanks.

[@OscarGarcia-kj6wt]

friend my astro van has a noise behind the glove compartment

[@Dan0rioN]

Squeely turkey sound when fan is on?

[@AlexBooth927]

Thank you!

[@alexandreblanc2842]

Your video helped me fix my GMC Safari 2003 as well ! Thank a lot ! I purchased the part on amazon, with good reviews, and same thing, it was slightly bigger and wouldn't fit in the hole, while screws were at the right place. I ended up grinding the support with a dremel, it's plastic anyways, just to let the larger part fit. Also, one of the screw head broke while removing, due to rust on one side, weird, so I had to drill the support to extract it. I used slightly bigger screw to replace, but went well. I have now the 4 speeds working right ! Thank you ! Also, because it's not obvious when you never did it, I used this video to check how the reservoir removal look like kzbin.info/www/bejne/q5CTf2BoppKWars Thanks again !

[@peterpiwowarski8689]

I wonder if there's a single one of those washer bottles in existence that still has its strap intact... 😂

[@MrJoey1570]

I'm on my 4th blower resistor harness on my 2004 astro I never run the blower on high

[@PineHollowAutoDiagnostics]

Did you install OEM resistor board? Dorman and other aftermarket boards get too high and fry the harness.

[@clarktferrill]

Any Idea Why my Safari high speed will not work....I have replaced resistor with brand new delco...replace fan with auto zone vdo brand...all other speeds are fine ..high speed nothing...

[@PineHollowAutoDiagnostics]

Did you look at a wiring diagram?

[@clarktferrill]

I don't know much about wiring .....so....I watch your video and see that you have the diagram ...you have taught me more in 5 minutes about wiring than I ever understood before...but where do I go from here...replace the switch on the dash perhaps...suppose to be a relay for high speed...I have no idea where it is located...I'm working with the removal and then install in reverse Chilton Manual...have pity on me...

[@PineHollowAutoDiagnostics]

Did you do the exact tests with the testlight that I showed here in the video? That is the most important step.

[@clarktferrill]

Yes ....all come up hot except the thin/smaller orange wire...no current...the last heavier orange wire is hot always...if there is a fuse and or relay under dash I can't identify it...that's where I'm hoping to find a fuse or relay gone bad...everything under hood checks out...I have all speeds except high speed on fan switch ..??

[@PineHollowAutoDiagnostics]

Well there's your problem! The small orange wire should be hot on HI speed to turn on the relay that is built into the resistor assembly. Next step is to check this same wire at the blower switch on the dash. If it's not hot there either, you need a new blower switch.

[@jking3892]

LOL i went through the same thing,, it wont fit!!

[@PowerScissor]

My Astro is driving me insane. Simple things like checking a spatk plug require removing so much crap it's not even worth it. People love these vans...but working on them has to be the worst layout of any vehicle I've ever owned.

[@marlinyoung1606]

What were you saying about that dorman one again hahahahaha

[@glenweist8189]

fix broken ball joint

[@OscarGarcia-kj6wt]

friend my astro van has a noise behind the glove compartment

[@PineHollowAutoDiagnostics]

Very good