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Old 11-14-2012, 02:12 PM   #1
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Thanks everyone for the advice especially as it related to jumping the stage 1 relay to see if I could make the fans run at low speed and the pins identifiaction needed to measure the resistance of the ballast resistors.

The car failed both tests. So it's time to unbutton the front and replace the two resistors. And, while I'm doing that, I get to clean the debris between the condenser and the radiator.
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Old 11-14-2012, 03:17 PM   #2
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Thanks everyone for the advice especially as it related to jumping the stage 1 relay to see if I could make the fans run at low speed and the pins identifiaction needed to measure the resistance of the ballast resistors.

The car failed both tests. So it's time to unbutton the front and replace the two resistors. And, while I'm doing that, I get to clean the debris between the condenser and the radiator.
You do not need to remove the bumper to get to the resistors, but it's a good idea to do so, and clean the radiators. Did that last weekend. Very easy.
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Old 11-21-2012, 01:00 PM   #3
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Can anyone suggest a good DIY reference (hopefully with some pictures) for changing the ballast resistors? I'm looking for one that gets at the resistors by removing the fender liner. Thanks
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Old 11-21-2012, 01:22 PM   #4
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Can anyone suggest a good DIY reference (hopefully with some pictures) for changing the ballast resistors? I'm looking for one that gets at the resistors by removing the fender liner. Thanks
hello thom.
if you jack up the car and look at the corners of the bumper from underneath, you should be able to see the resistors (one on each side).
i'm not sure about the location of the connector, but i can have a look and post a picture later.
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Old 11-21-2012, 02:13 PM   #5
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Meir:

I found a really simple DIY at http://www.renntech.org/forums/tutorials/article/40-removing-and-installing-ballast-resistor-for-the-radiator-fan-motor/. Essentially, it says to:
  1. From underneath, unclip the old resistor
  2. Cut the wires about 1.5" from the old resistor
  3. Do the same with the new resistor
  4. Slide heat shrink over the old wire and the splice the new resistor to the old harness using crimp connectors
  5. slide heat shrink over the new splice and shrink using a heat gun
  6. clip the new resistor into the bracket

This was for a 996. I'll give it a look and see if this as easy as it sounds. If not, I'll either have to pull the liner or fender off and replace the resistor with its harness.

Thom
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Old 11-21-2012, 05:31 PM   #6
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Meir:

I found a really simple DIY at http://www.renntech.org/forums/tutorials/article/40-removing-and-installing-ballast-resistor-for-the-radiator-fan-motor/. Essentially, it says to:
  1. From underneath, unclip the old resistor
  2. Cut the wires about 1.5" from the old resistor
  3. Do the same with the new resistor
  4. Slide heat shrink over the old wire and the splice the new resistor to the old harness using crimp connectors
  5. slide heat shrink over the new splice and shrink using a heat gun
  6. clip the new resistor into the bracket

This was for a 996. I'll give it a look and see if this as easy as it sounds. If not, I'll either have to pull the liner or fender off and replace the resistor with its harness.

Thom
that makes sense.
here are some photos i took earlier this evening.

if you look at the lower corner of the bumper, you will see a "hole" between the bumper and the plastic cover.



here you can see the resistor.




the wires go up




and ens behind a plastic cover, attached to the back of the fan.




i spent couple of minutes trying to remove this cover, with no success.
it looks like its held in place by two clips that are very hard to reach.
the way i see it you have two options.

1. cut the wires and connect the new resistor as described in the DIY you found.
if you go that rout, i suggest soldering the wires, and using a water proof heat shrink. this type of heat shrink has glue in it, and i think you can get it at radio shack. as you can see, the resistor is located in a place that can easily get wet.
you don't want to have corrosion issues after the winter.
2. remove the bumper, air scoops and radiators. remove the plastic cover at the back of the fan, and plug in the new resistor.
if you have the time, go for the second option. it is not that complicated, and you also get to clean all the dirt accumulated on the radiators.
you will be surprised do see how much crap will come out of there.
good luck, and happy thanksgiving.
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Old 11-24-2012, 02:38 PM   #7
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I'm going to try Meir's suggestion in the next day or two. Before I do, I have two questions.

1. The resistor has two different wire connections. One is a plug and it's clear how to attach it. The other is two bare wires. See picture



I presume these bare wires attach to the fan motor. Does anyone know how they actually attach to the fan motor?

2. If I try to do this job by taking off the front bumper cover, can I reach behind the radiators and make the repair or do I have to also loosen the fender liner. The shop manual says to fix by removing the liner, but I heard the job can be done by removing the bumper cover.
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