2003 LS blower motor resistor removal

Zepaman1

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I Need help with 2003 Lincoln LS blower motor resistor removal. I have searched and found the procedures for other years of the LS and they do not appear to be the same. I have the glove box and blower motor removed and can not get the blower motor housing out so the resistor can be removed. I seem to be missing where some fasteners are to completely remove the housing. I have found the nut on the engine side on the firewall that is attached to a stud attached to the blower motor housing and have removed it but the housing is still attached rock solid. Does anyone have a step by step procedures, diagram, photos, or a cheat?
 

joegr

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It's the same for 03 as for other years. You have to remove the entire dash.
2006 Lincoln LS Workshop Manual
2006 Lincoln LS Workshop Manual

There are a couple of possible hacks to avoid this, and I think that I would probably try one of them. One is to cut up the air box to get the speed controller out and then glue/tape it back together. The other is to mount the replacement speed control under the dash with a small 12V fan added to blow on it to keep it cool.

I'd experiment on one in a junkyard.
 

Zepaman1

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Thanks Joegr, this is very depressing that they engineered a 40.00 parts that is known to fail and need replaced into a place that it cost over 1000.00 to replace at the dealer. I am going to try cutting the blower motor housing so the resistor can be removed and then epoxy it back together.
 

joegr

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Any part can fail. You can't make a car that has everything replaceable with very little work. I would disagree that the blower speed controller is "known to fail." I have heard of a very few failures, but most are doing fine, including the ones in my two LSes that are approaching 250K miles.
 

oddball

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I can attest the gen2 blower controller is a surprisingly robust unit. It'll still fail if it gets too dirty or isn't cooled. Some of them I pulled from the junkyards are coated in nicotine, so I bet they had a tough life. The Gen 1 unit is much simpler, but doesn't have any self-protection circuity so the bit transistor will happily sacrifice itself.
My removal method involves a hammer, so, uh, don't listen to me. That lower blower housing is a real PITA. Then Gen 2 cars are fairly common in u-pull-it yards so you should be able to find a couple to practice on and use their controllers.
 

sam3222

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I know the blower motor controller requires either the dash pulled, or some surgery on the ductwork...but what about the blower motor? Can this be replaced easily without removing the dash?
 

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