Blower motor only works on High (4)

Ok-today I went out to the 2006 TDI only to find that my blower motor only worked on high (4). I read in the forums that the resistor pack is messed up. pn 1K0 959 263A. I priced this in several places with the cheapest being IDparts.com at 39.95 plus shipping. While searching I ended up at the VWVortex.com and found this post: http://forums.vwvortex.com/showthread.php?2665283 . Interesting idea that the thermal fuze is the only thing that might be blown. I did not have any noise from the motor itself so I figured it was worth the effort and $2. I tested the thermal fuze and it showed as open when unplugged so it seemed logical. I ran over to RadioShack (across the street even though their selection is not very good anymore). The thermal fuze showed (had to look with a light and magnifying glass) 240C. RS had a 226C and I figured a little less is safer (we'll see how it works over time) Part # 270-1321. Soldered it up using rosin core to clean the surface first and then soldered it on. Total time about 5 minutes. Plugged it in and it worked perfectly. This may not be everyone's solution but for $1.94 with tax it sure was worth the try before spending $50. Besides if it blows again I might need a motor but I can replace the thermal fuze again for another $2 and use the $50 toward the motor. Try it before you give in to buying a new one. The original parts are better to keep in my opinion and that means I still have OEM that has worked for a few years now.
FYI-this is not an advanced repair-any novice can do it if they have a soldering iron.

Info-this is non climate control and a MK5 but it should work on any Jetta or other VW with a thermal fuse.

The usual failure mode is that a worn out motor draws excessive current destroying the resistor pack.

If your time is worth nothing then keep changing resistors. I would change the resistor pack and the motor and be done with it..............

If you have further problems, try lubricating the fan and fan motor bearings.

DanG144, how do you lubricating the fan and fan motor bearings? What kind of lubricant do you use to do that. I pulled my out because it was squeaking. Wow was it dirty, I use my air gun and blow all the crap out of it and it is working great with no squeaking. But I would like to lube it also.

Thanks,
Mike

Has anyone come up with a filter upstream of the fan instead of downstream? Wouldn/t that solve most of the fouling issues?

nice to know, i read the other post they mentioned using silver solder as normal solder might melt. (thought i might mention it ) zleem60 where do i start on removing the fan? if u point me in the right direction i can get it from there? under hood or dash?
thanks

so i took a look for myself today, thought this might help other people.... how to replace blower fan 2006 jetta... easy as pie, its under the glove box, there a foam shield held in by 2 plastic screws, remove them, the fan is right there, unplug the electrical connector, then rotate the fan and it pops out. my was squeeling a bit so i drilled 2 small holes in the bearing covers at each end to allow me to pump a bit of grease in there using a needle on my grease gun. popped it back it, golden sounds great. should hold it off for a while. the fan motor needs to be removed from the plastic housing to do this

I attempted to replace the resistor pack in my 06 Jetta this weekend (same symptom, heat is only working on 4, 1-3 speeds not working). After i removed the glove box I could not find the resistor pack. Can anyone help me locate this? thanks.

It's under the glovebox

nice, thanks a lot 20IndigoBlue02

Came across this thread as I just got the issue of the blower only working on 4. Followed the repair as shown in this video: https://www.youtube.com/watch?v=mLWn3J6QUXk

I also followed the linked guide on lubricating the blower motor. The blower wheels was a little stiff and I lubed it with silicone. So far, so good. I bought some extra thermal fuses at RS and I found a knock-off blower on Amazon that I bookmarked in case it happens again.

Just what I was looking for thank you !

$40 Amazon blower has been working fine for me for 18 months now; replacing fuse before going that route lasted less than one month.
Good luck with the repair.

Nuje said:

$40 Amazon blower has been working fine for me for 18 months now; replacing fuse before going that route lasted less than one month.
Good luck with the repair.

Click to expand...

I was thinking to just do the resistor for now. The fan is also under glovebox right? I have 2006 Jetta 2.0T

Went to VW just to ask how much parts are, in Canadian dollars he quoted me $82+tax for resistor and $256+tax for blower. Crazy high, I've seen those resistors for around $10 in eBay, is that not the same thing?

When i first got my tdi, the fan squeaked and only worked in high.

I replaced the resistor pack with a junkyard part.

I blew the motor with compressed air and soaked it with wd40 (i do this every year when i replace the cabin filter)

My blower also sqeeks a bit. I might try this once I get around to fixing this no-AC problem.. Geeze it's getting hot out here. Been without AC for maybe two years.. Enough is enough.

Hello _my 03 jetta tri blower only working on 4 and the ac will not engage when fan runs. I could live with high speed for now but not without a.c... Is this normal??? Just a bad fan/thermal fuse? Thanks!

Sounds like a blown resistor pack to me, dx1001.

But like mentioned above, the resistor blew for a reason (too much draw - most likely from the fan), so I'd be looking to replace both.