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Old 11-03-2019, 01:29 PM   #1
some dude
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Default Intermittent blower motor

2006 WRX TR. I have the manual controls, no auto temp stuff.
2 days ago my GF turned blower on but nothing happened. Then a minute later, it fixed itself and it blew air normal.

Today, it happened again. No fan on any setting. While not working I noticed if I turned it to 3 or 4 (max setting) and turned it back to zero, I heard a small click from my left knee area. Maybe a relay click? But no airflow.

I drove about a mile and tried it again and it was working again. Worked fine for rest of trip (30 minutes)

Only other symptom is blower motor has a slight tick that is tied to it's speed.

Could anyone help me on diagnosing this? What should I be checking of it happens to stop again?
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Old 11-03-2019, 01:50 PM   #2
Mulder
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The tick may be something (leaves etc) stuck in the blower. Do you have the cabin filter? That usually prevents this.
Pull the glovebox and open the filter housing, remove the filter if there is one. Then you can check the blower for foreign matter and see if it turns easily. If it's tight the motor may be bad.
Beyond that check the connectors at the motor, switch and resistor. Sometimes a poor connection results in burned contacts. Pull the resistor out and inspect it.
The relay could have burned contacts as well, but this could be the result of high current draw if the motor is bad.
Go through all the above and you'll probably find your issue(s).
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Old 11-03-2019, 05:23 PM   #3
Cougar4
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I assume that when the blower is working you can use any of the motor speeds. If so my thinking is the blower relay may be causing the issue or the blower motor itself may have some brush issues. Checking for power at the motor while the trouble is occurring will tell you how to proceed. If you have no power to the motor then the trouble is most likely with the relay.
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Old 11-03-2019, 08:38 PM   #4
some dude
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Thanks for the replies, yes I have cabin air filter. It's been changed twice.

I will go through what you both said and go from there. I will try to reply here with any new information.
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Old 11-04-2019, 12:01 AM   #5
08SpecB_DE
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The next time the blower stops working, give it a few thumps with your fist. If it starts working, time for a new motor.
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Old 11-13-2019, 09:30 AM   #6
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Ok, small update.
When the blower stops working completely, a quick light whack or two on the blower area gets it going again.
I've also noticed that the blower is slowing down, not blowing air as fast as it used to.
It also has a light tick that is tied to blower speed.

I'm looking at this blower motor on Rock Auto
https://www.rockauto.com/en/catalog/...wer+motor,6916

I also see a separate part for the resistor.
I'm not seeing any mention of new resistor coming with new blower.

Is my current resistor going bad?

Any help on the resistor would be helpful.

Should I just buy a new resistor?


I re-read Mulder's post and I have not inspected it yet. Sorry, I guess I need to dig into it to answer some of the things he brought up.
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Old 11-14-2019, 01:50 PM   #7
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From what you have stated about the problem it seems the motor itself is causing the problem. Unless there is an issue with the connector going to the motor. Since tapping on the motor allows it to at least get it moving the problem is most likely inside, the brushes perhaps. The resistor pack can be an issue at times but it sounds like it is okay. Do all the speeds seem to work? If so, you are good there. By following the wires going to the motor they should tie to the resistor pack, which is installed on the ducting for cooling the resistors.
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Old 11-16-2019, 03:36 PM   #8
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Pulled it all out. Blower spins freely.
Resistor has multiple burn spots in it.

#2 blower speed went out like a year ago. This is probably what killer that speed.

Here's a shot of resistor, YouTube is easiest for me to post.

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Old 11-16-2019, 04:06 PM   #9
CaptainSlowbaru
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Just for the hell of it, check the blower motor connector and make sure it isn't burned or melted. I've seen several Foresters in that age-range with burned/ melted connectors.
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Old 11-17-2019, 02:34 AM   #10
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^ I'll check tomorrow.

I also found the blower hamster wheel had a dark brown almost black powder that was on most of it's surface. The fins were pretty clean but near the middle and around the bolt in the center shaft it was coated in this stuff.

Just thought I would mention it. Is it the material from electric motor brushes?

I wish I took a video of it before I wiped it off.

Anyway, I'll replace resistor first, check motor connector plugs, and report back.

Thanks for the replies
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Old 11-17-2019, 06:35 AM   #11
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If you can safely do so, try connecting 12V directly to the motor while you have it out and see what it does.
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Old 11-18-2019, 10:47 AM   #12
some dude
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I connected the blower to 12V. It spun up and sounded quiet.

I tilted the motor upside down and tapped out the brush dust.
Kind of a lot came out. I'll post video to show how much.
What happens when the brushes run out of material?
I could just run my current setup as it still works (once I get my new resistor).

The electrical connector appears inharmed/ not melted.

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Old 11-18-2019, 10:18 PM   #13
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Since your motor seems to work okay the real trouble may be with the blower relay. If you still have trouble after the resistors are replaced the relay and selector switch are what is left.
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Old 11-21-2019, 12:34 AM   #14
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Your blower motor is going bad. A few taps tomget it going again is the indicator. You can replace the resistor as well if you choose, but it's not necessary unless not all blower speeds are working.
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Old 11-21-2019, 05:37 PM   #15
some dude
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Replaced the resistor, left old blower motor in it.
Everything is back to normal. I also got my #2 fan setting back again!

I'm going to run it like this. Dont know how long current motor will last given how much brush material came out of it.

I'll try to update this thread if/when the original motor dies.

Thanks for all of your help.
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