Chrysler Repair: 99 Cirrus Fan Blower resistor keeps failing, coolant leak, intake plenum


Question
Hi theree...  I have a 99 Chry. Cirrus, and the blower resistor keeps going bad.  I have removed and replaced with new ones several time.  It appears there is rust on them, which would indicate it is getting wet and causing failure.  I had the windshield replaced to see if it would help but once again only the high setting will work (until I replace the resistor again).  
Any ideas on how this could possibly be getting wet? Or if there is another problem causing this?

Answer
Hi Shawn,
One possibility is that there is an obstruction in the drain for the air intake plenum that is causing water to back up and go into the air intake. I would remove the grill at the front of the windshield and see if you might have a build up of leaves at the far end on the passenger side which is where the drain hole is likely located. The other trick I have heard for some other models is to leave the air distribution lever in the "recirc" setting just before turning off the engine so that the air intake door is closed, which would also reduce the amount of water coming in from the outside.
Wow, replacing the windshield is the supreme effort. I hope these two suggestions will solve your problem. The last possibility is a coolant leak in the heater core and I'm not sure you wouldn't have noticed that by the smell of coolant and the wet floor mat, and even then I can't be sure it would get to the resistor block anyway. Just a last idea... Except for one more: might the blower motor be drawing too much power due to dry bearings or some other binding up? But the rust is probably the tell-tale.
Roland
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