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Re: Cooling fan resistor- easy to replace resistor only
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Posted by Jim Moore [Email] (more from Jim Moore) on Sun, 19 Jul 2009 19:47:42 Share Post by Email
In Reply to: Cooling fan resistor- easy to replace resistor only?, JamieZ, Sun, 19 Jul 2009 17:31:24
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I just replaced the one in my daughter's 1999 9-3 today. It's a bit of work, but considering it cost me about $5 to repair it vs. $400 for a new fan, it was well worth it. Getting the fan out of the car was a bit of a pain; the pipe/hose going from the PS reservoir to the PS pump had to be disconnected, plugged, and re-positioned. And the one stud sticking up from the exhaust manifold to secure the heat shield was in the way. I couldn't get the stud out, so I had to force the fan past it.

I got a .2ohm 50w resistor just like the one shown in the attached link. I work at a machine shop so making the mounting plate was no problem. Just be sure you wire it up right; the OEM resistor has three leads and the replacement will only have two. Two of the wires on the OEM resistor are actually attached to one end of the internal resistor. It went like this on my car; there is a two-conductor plug with a black wire and a green wire. The black wire is ground an attached directly to the fan motor. This wire is left "as-is". The green wire is the low-speed wire and attached to one (either) end of the new resistor. I also had a one-conductor plug with a white wire; this is the hi-speed wire and must be connected to the other wire coming out of the fan motor (green w/yellow stripe on mine) and also to the other end of the new resistor. You'll need to extend the wires after you cut the OEM resistor off. Be sure to us a heavy gage wire (12ga should be OK) as the fan draws a lot of current. The wires attaching the new resistor should be soldered in place. Any other connections (to extend the wires) can also be soldered or butt-spliced with crimp connectors. Either way, good connections are important at high current levels.

Let me know if you have any questions.

posted by 71.232.19...

http://www.geocities.com/pmiczek@sbcglobal.net/NG900SET/Rad_fan/fan_res.html?200727

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