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For 1999, the Quest was redesigned at Nissan Design America in San Diego, California, under Diane Allen, during 1993 and 1995.

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Why does my blower motor Resistor keep breaking?

I drive a 2002 Nissan Quest. The blower motor will only work on the highest setting because the blower motor resistor keeps breaking. I changed the blower motor resistor about 7 times. Settings 1, 2, & 3 will work with a new resistor but not for long. Most recently, I also replaced the blower motor itself, along with a new resistor. The resistor still blew out with the new motor. I am not sure what could be causing the resistor to constantly blow out.

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@theartistq that is a tricky one. If your blower motor resistor continue to fail you do want to do a few things. First check the amperage that the new motor pulls. If it is to high then there are issues with that. After that you do want to check for corrosion on the wiring and connectors since that can cause heat which may cause failure. Next is to check the airflow to ensure that it is unobstructed. Leafs, mechanical obstruction, water as well as other debris can cause overheating/shortening out of the resistor. you also need to consider the fan speed selector switch. Make sure that it is not the switch that shortens it out. Check for anything unusual at this time.

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I would add trying to run this while monitoring the temp of the resistor. That might be more conclusive then measuring amperage, though it may not be possible while installed. The amperage is sort of an unknown, unless it is marked on the motor, as long as it is less than the fuse rating. If the amperage is nominal and the temp is high, then insure the resistor is getting airflow if the design allows for that. Last ditch effort - install a higher wattage resistor if space allows and or remount it to a heat sink.

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Pretty lame answer. All true but the root cause is improper and inadequate design engineering work. Not doing a FMEA failure mode effects analysis with a multidisciplinary team with design, manufacturing, product quality, supplier quality engineers in the cross-functional team chartered by the chief product engineer.

I might further add as this could be a fire hazard a complete SHA safety hazards analysis should have been performed for this component.

Both of these happening are the direct responsibility of the Chief engineer on the project.

If all of this fails it's kicked to service engineering where they chartered to develop a fix or work around. This may or may not include issuing a service bulletin or a recall. Could be mandated or voluntary.

Key is having the resister,fan switch,fan motor,fan and wiring harness manufacturers work in a systems approach together early on. This is when you have the best opportunity to obtain the best quality, reliability and the sweet spot for reducing costs and obtaining the maximum TCO.

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It's a little late to fix any of that, so your answer is more lame than the last!

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Amen to that! Definitely a little late!

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@ewfalken @nbevins420 I do hate to give lame answers. I like to at least start out simple and with more feedback we can usually provide a less lame answer:-) I appreciate your support with that.

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Unclebudsfarm@

Due to blower chirping and noise I Replaced 2005 volvo xc90 cabin ahu blower plus new resistor. Bench-tested on floor of car - all dial fan hi-low speeds worked fine. Installed into housing. Plugged in, then started engine fan went right to HIGH. Turned off engine. Blower keeps running high. Had to plug-in / unplug each time fan used for AC or heat. Ordered another blower and resistor after 3 mos. Same outcome. Bench test OK all speeds . Reinstalled - HIGH only and runs after engine off. THIS IS NOT CONDENSATE DRY BLOW after-run Volvo mold control feature as so many keep suggesting. 2 New blowers & resistors. Works fine bench test out of box. But after reinstall speed jumps to high and runs after engine off. Plug connector hot after constant high run. Could resistor be shorted so quick both times? Help

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2005 volvo xc90

Also... No apparent restrictions or blockage. Airflow pretty brisk. Plug does get pretty warm after run - AC or heat

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