Low Speed Fan Resistor Alternative
 

So right side radiator fan wasn't running the other day as the left side kicked on. Didn't work turning AC on, so I jumped the low speed relay (#21 for right side low - Bentley's has a typo for this) and it still did not operate. I jumped the high speed (#22 for right side high) and the fan worked so it must be the low speed Resistor.
$120 to replace just the resistor and no aftermarket - Are You Kidding me.
$150 to replace the fan with resistor, now that actually seems reasonable.
I'm so cheap so!!!
There are articles on buying an air cooled resistor (.5 Ohm, 100 watt) - $9.95
So I bought (2) for when the left side goes out or I screw up
I was going to have to splice the (3) wires (All Green, Green White strip, All White) If I bought the Porsche resistor so this work was the same
Mounting was the question. There is a metal tab at the back of the chamber where the fan was. I had to simply drill a hole through the plastic, it was at the perfect spot to mount one corner.
I used #8 1-1/4 stainless steel bolts, nylon locking nuts (2/bolt) and plastic wire hangers.
http://986forum.com/forums/uploads02...1510532473.jpg

Wiring - All Green wire goes to ones side
- Green/White strip wire and All White wire both connect to the other side
I did not soldier. I used crimp fittings and heat shrink tubing. I may pay for that with time.
http://986forum.com/forums/uploads02...1510532696.jpg

I mounted and used a backer for the other hole. I had the inner fender off so I could get to this area easily.
http://986forum.com/forums/uploads02...1510532818.jpg

And the final product from the front
http://986forum.com/forums/uploads02...1510532888.jpg

Nice writeup!

Did the same fix, very cost effective and so far dependable through the summer after 5,000 miles. If I recall, I used 50w registers slightly below 0.5ohm, and the original clamp could wrap it around just like factory install, after cutting off the mount ears.

Also added a toggle switch to manually turn on/ off the fan, so I got full control to keep the engine cool consistently in heavy traffic during summer, plus easy to diagnosis for bad fan/ register with a flip of the switch.

If you are concerned about summer heat in slow /no-go traffic. suggest the simple mod of relocating the Temp sensor for the engine compartment purge fan.If you reposition it closer to the cylinder head , it will turn on the exhaust fan sooner/longer.

Ready to install resistor
 

I'm about to install a replacement resistor for rad fan.
Is 100w 1 ohm resistor ok?

Currently not running,at least one lead is corroded off the original.

Can't justify $150 for a $5 resistor

Thx in advance
2002 base

The original resistor is about 0.5 ohm. If you have a couple of 1 ohm resistors, put them in parallel and you will be fine.

I replaced mine with a single 0.5 ohm (0.5R) 100W resistor about 6 months ago and it has been working fine ever since.

Thanks!
 

I ordered two, so I'll parallel them. Hope to have them tomorrow. Makes me nervous not having them working, especially with weather in the 90's! (Central Florida).

Thx Again!

So the product I used was that Arcol HS 100 R5 J as pictured. it is .5 Ohm therefore I only used 1
The fan works as expected for low speed
I did buy 2 so I was ready for the other fan's low speed to die at some point.

Installed in parallel, pretty easy.
Did not even have to pull the wheel.

I'll post some pics tomorrow

Working as expected

Just bumping the topic for a good, simple repair.
 

One of my '99s had been running a little hot for a while and I thought it was just from debris in the radiators. Over the course of a year, I cleaned the radiators and replaced the water pump (It was due anyway) It still was running on the 0 in 180 where my other cars would be on the 8. Then, on a long drive it got worse and the AC was blowing warm. BOTH radiator fans had quit working and I had probably been driving for a long time with only one.

I still had a pair of these resistors (if parts are cheap, I buy extras.) from when I did it a few years ago on another car. Once I recognized the problem it was a quick and easy fix.