Blower motor resistor

Jerry if IIRC the biggest issue here is not so much the resistor that fails, it is why it fails. That is because the blower motor has so much resistance that it causes a current draw exceeding the resistors limitation. In other words, the blower is dirty. Your thoughts?
 
The motor windings do start losing resistance over the years as the shellac insulation starts wearing through. That causes the motor to start drawing more and more current which starts taking out the switch, switch wiring, and the resistors in the resisistor pack.

A good motor typically draws something like 13 amps, bad motors can easily draw 25 amps. The normal startup current can be significantly higher.

So yes for sure, an aging or bad hvac fan motor can take out multiple components. :)
 
Be aware that there are two different types of blower resistor, depending on the year of your Wrangler TJ. Make sure you get the right one - look at the parts list for your particular Jeep or look at your old resistor as they do look different. That later model ones are a bit cheaper than the earlier model - Mopar = $15 vs. $30. I ordered a Mopar one through Amazon for my 2005. This YouTube video shows you how to swap it out. I didn't need to disconnect the green wiring harness when I did mine. It's a relatively quick, straight forward job, just in an awkward place to access.
 
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