Bill Ball

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Wally's wisdom indicates the resistor pack. Is this thing serviceable/repairable?

ROG100

Bill,
I have a new one somewhere if you need it.
Pay me what I paid for it if you need it.
Best,
Roger

worf928

Yep. IIRC Pirtle's got a write-up. Summary: Loosen the blower motor so that you can get your arm into the duct work. Unplug resistor pack (next to A/C freeze switch.) Unbolt resistor pack. Proceed in reverse for new resistor pack. The hard part is the blower motor. It doesn't have to come out but you do have to get all three bolts out of it so that you can move it around. One of them is from the interior side behind the parcel tray.

GregBBRD

Bill:

The power for the fan goes through the resistor pack for speeds 1,2, & 3. Speed 4 is direct and goes around the resistor pack. The pack has an "overheat" circuit in it. It has a contact that separates when it overheats. This is the usual problem when the first three speed fail....the contacts get dirty and don't make contact. Try tapping on the resistor pack from the outside with a screw driver....this will sometimes fix them for years.

If this fails, you can replace the pack without removing the fan. Pull back the boot and tie a string or wire onto the resistor pack before you remove the screws. Fish the old one out with a "grabber" tool and tie the new one onto the string/wire. Pull the new one to the hole, line it up, and screw it in place. If you can do this without dropping any of the screws down into the never,never land....you an official 928 Ninja. Keep your magnet handy.

greg

Wade T

Ack! I have the same issue. Didin't think it would a resistor or that exotic of a fix.

Thanks for the info.

RyanPerrella

I want to try this out just to see if i can call myself a 928 Ninja, I like that one Greg.

I had this problem too for 3-4 days, then for no reason it was ok and hasnt happened since.

Weird stuff

Bill Ball

Roger: Thanks for the offer, If I can't get it working with a little clean-up, I''l take you up on that.

Dave: Thanks for the reminder to check Pirtle.

Greg: Great tips. I banged on the resistor pack a bit, but it's still the same. So, I'm pulling the pack out using your ideas. I've already lost a few other nuts and bolts into the abyss.

RyanPerrella

Bill

When you pull it, its also been suggested to spray it with an aerosol cleaner. Maybe something thats electrical sensitive. Ive heard these get all kinds of debris build up and once cleaned can work well again. Maybe a light scrub with a brush and some solvent, then blow dry with compressed air. Of course if you reinstall it and it still dosent work then that sucks. In which case it pays to buy a new one the first go around.

Bill Ball

Ryan: Will do. You can plug it back in an test it before reinstalling.

RyanPerrella

yeah then try that

Let us know how it goes and how irritating it is too. although Ive heard of some rennlisters doing the complete swap in 45 minutes. I am sure that was the 3rd or 4th time though.

Bill Ball

I got it out. Before I loosened it, I screwed a large sheet metal screw into an open hole in the backside of the pack and tied a string on to it. Removed the screws and let it fall into the inlet, although it wasn't going too far. I pushed in the boot and could see the pack. I fished out the pack with a magnetic probe. I was able to squeeze it out without loosening the fan housing, although it was a tight squeeze.

Opened it up and cleaned liberally with contact cleaner. I checked the resistance of each of the 4 coils and they matched the clear markings on the pack. I don't see any contact except one in the center. I gather that is responsible for the "magic blower syndrome". But, as I see it the 4 coils which differ in resistance determine the fan speed. They are fine. With the pack out, the fan still works the same - nothing on 1,2 or 3. If the 4 coils are fine, could it be something else?

GregBBRD

Bill:

The resistors are always good. The contacts are the almost always the problem. I've only ever seen one that had a wire to a resistor broken. Take a look at a wiring diagram and follow the power path.....it gets very clear. If you bypass the contacts, it will work fine.

The reason the fan works the same with the resistor out is that the power goes around the resistor pack for high speed fan. Only the lower 3 speeds go through the resistor. If you unplug the resistor, the same thing is still going to occur.

Trust me....I've been through this a couple (hundreds) of times.....

greg

danglerb

Could you check the thermal something?

Kind of reminds me of the speed control on a old golf cart we had, metal bars instead of coils though.

Unplug and plug fixes a lot of stuff too.

Bill Ball

Greg:

I don't see any contacts besides the single one in the center. The resistance coils are wired directly to the plug pins. You means the plug contacts?

danglerb

Purely guessing, the coils are wired directly to the pins, external wiring and the switch routes the current through a selected coil, and the thermal contacts are part of the series circuit. When it gets too hot, the contacts open. Check those contacts.