HVAC Blower: Problem and Solution. 95 RRC

[Ian95rrc]

These where the symptoms.

The blower is intermittently cutting out completely. It always would stop working if
I had it on setting 4 for longer than say 5 min. However, it always worked when I brought it back a notch to the 3 setting. Now it is intermittently going out completely leaving me with no blower at all. It will just stop working on say the 2 setting.

SOLUTION:

Replace ignition load relay located behind passenger footwell cover on left side. There are 3 relays on the bottom; 1 yellow - 2 green. The green relay located in the center is the correct relay. The other green relay(for the wipers) can be swaped to test if the relay is bad.

 

[ptschram]

Ian:
It likely isn't the relay, but the switch. It's a common problem with the Discos as the switches are poorly suited to the amount of current flowing.

I'm on the fourth or fifth switch in my Disco.

 

[Ian95rrc]

Nope. I was told it was the absolutely the switch before.

Replaced switch with no luck. Troubleshoot the system and I found that relay to be bad. Replaced the relay and all is well.

 

[Ian95rrc]

All I'm saying is if you have these problems, take 2 minutes and check the relay before you spend a lot of time and money on replacing the switch.

Perhaps the problems I have always had with the blower cutting out on the 4 setting was the switch. However, I definitely had a bad relay causing the blower not to function at all.

 

[ptschram]

Wow! I've changed countless switches and have never seen the relay fail. With the exception of the cruise control relays, the relays seem to be pretty robust.

 

[Arthur 1995 LWB]

Is the switch available by itself? Is the relay available cheap somewhere?

Wife's 95 Disco cuts out like yours, Ian. That fan switch does not slide nice and smooth like my LWB's. Over the summer, hers cut out at various fan speeds. Slide to 0, then back to 1, 2 etc. always worked. Might need both items changed.

Did the load relay affect how cold your A/C blew? I also felt her fan did not blow as fast as the LWB's at various fan speeds - that might be nothing. Who knows. Should be grateful it works at all

 

[Ian95rrc]

Apparently you have to buy the whole control unit even though you can remove just the switch. It's a pain in the ass to replace. If you want to test to see if it's the relay just swap it with the wiper relay next to it. I think the relay is around $10.

No, I don't think that relay has anything to do with the AC. The fan speed is still the same.

When the blower just cuts out and comes back when you mess with the switch, I think you have a bad switch. My problem was that no amount of messing with the switch would bring the blower back. It would come back after I shut off the car and left it for an hour or longer then restarted. Hence, why I think it definitely was the ignition load relay.