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EA82 Fan Power Selector Fix
Posted 12 January 2013 - 02:58 AM
Not only do the internal connections of the switch wear out, but there is another assembly completely separate from this one that affects heater function. There is a resistor assembly just above the passengers feet held on by three screws which consists of a small circuit board, with rows of spiral wire resistors. This is what actually controls the speed of the fan. There are three coils, which progressively grow in size. The smaller one is fan setting one, the medium, setting two, large, 3, and number 4 is full power, no resistor. As these get old, the thin wire breaks, much like a filament in a light bulb, as these resistors are lost, so are their appointed speeds. This is why many of you have the number 4 as the only working setting.
Now I just replaced this with a spare resistor assembly from an 89 DL. Expose the assembly by removing the three plastic pressure fit screws in the panel below the glove compartment. Remove panel and look under. A 3x1 inch black plastic component with an angled arm and a set of wires running from it is what you are looking for, it's fairly obvious. Remove these screws and unplug the unit. Swap in the new one and do everything in reverse. Voila! All 4 heater settings:headbang:
If you don't have an extra resistor assembly, you may very likely be able to fix your existing unit by resoldering the resistor wire to its original state. It is likely soldering some modern resistors to the circuit board would provide for a longer lasting fix to the problem.
If this doesn't entirely fix the problem, it is likely your actual switch mechanism is the culprit.
Hope this was helpful!
Posted 12 January 2013 - 04:21 PM
Posted 13 January 2013 - 04:28 AM
Posted 14 January 2013 - 12:50 PM
Posted 14 January 2013 - 01:10 PM
Does anyone know the resistor values? So you could rebuild the resistor pack.
Wait i just read tommba's post again... going to radio shack on the way to work.
Edited by tractor pole, 14 January 2013 - 01:14 PM.
Posted 14 January 2013 - 08:03 PM
Fixing the existing one is harder than it looks, as the resistor wire is very hard to solder.
If the resistor is burnt out in the middle, there is not much you can do to fix it. Maybe squeeze it together, and hope it reconnects? It may work for a while.
If it is burnt out close to the connection, it may be possible to resolder it. Scratch the wire to try and get to a clean, solderable surface, heat the existing blob of solder, push the wire into it and add more. Pray lots! I got a couple of years out of a fix like this.
Posted 14 January 2013 - 09:46 PM
Posted 14 January 2013 - 10:13 PM
Nice work on the pics kerandt, I'm sure it will help save others some confusion. Mine had dog hair too, as well as a couple pennies resting on it. The design seems weird to me, I don't understand why the resistors have to be exposed to the moving air within the blower ducting. Maybe it has something to do with temp control as well?
Correct. Using a resistor is an EXTREMELY inefficient way of dissipating current for a high load. So they create A LOT of heat. It is, however, an extremely simple design, and since power draw isn't really a concern, that's how it's done.
But since it needs a lot of cooling, it has to be in the ducting.
EJ ones actually have a cage around them for better protection. I keep meaning to grab a couple EJ ones and see how I can adapt it to work in the GL. Every GL I've ever seen in a junk yard has a blown resistor pack, it's extremely frustrating trying to get a good used one. I haven't even seen a junked GL for a while up here. They've all rusted out.
One thing I have considered as a fix is just doing a solid state circuit like a PWM board with preset resistors that the heat selector choses for the PWM. It would be a plug and play solid state fix to this stupid problem. Because honestly, I'm tired of only having three and four.
Posted 14 January 2013 - 11:29 PM
Resistor block wattage
Blower motor resistor pack
GL-10 Blower Switch
Heater blower missing speeds replace
Edited by kerandt, 15 January 2013 - 12:01 AM.
Post Titles . . .
Posted 15 January 2013 - 12:40 AM
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