1996-2000 Dodge Caravan HVAC Blower Motor Resistor Replacement Guide
If your Caravan's fan only works on high or not at all, this guide is for you.
- The most common symptom of failure is the fan only working on the 'high' setting.
- This is a very common problem on 1996-2000 Dodge Caravans and is an easy DIY fix.
- Always inspect the electrical connector for melting or corrosion; replace it if damaged.
- If a replacement resistor fails quickly, the blower motor is likely faulty and should be replaced.
Symptoms of a Failing Blower Motor Resistor
A bad blower motor resistor in your 1996-2000 Dodge Caravan has very specific symptoms. The most common sign is when your fan only works on the highest setting. This happens because the high setting sends power directly to the blower motor, bypassing the failed resistor. Other symptoms include:
- Some fan speeds not working while others do.
- The fan not working on any speed.
- A burning plastic smell coming from the vents, which indicates the resistor or its wiring connector is overheating and melting.
- Inconsistent fan speed, where it seems to surge or change on its own.
Check the Connector First
Before ordering a new resistor, it's a good idea to inspect the old one. A common issue on these Caravans is the electrical connector melting due to overheating. If your connector is melted, you will need to replace it along with the resistor to ensure a lasting repair.
Choosing the Right Aftermarket Part
For a common failure part like this, aftermarket brands offer a reliable and affordable alternative to expensive OEM parts. The quality difference for a simple resistor is minimal for this vehicle, and aftermarket parts from reputable brands will restore function just as well. Brands like Dorman, Four Seasons, and Standard Ignition are well-known in the aftermarket and produce direct-fit replacements.
| Brand Tier | Brands | Typical Price Range | Notes |
|---|---|---|---|
| Standard Aftermarket | Dorman, Four Seasons, Standard Ignition, Global Parts | $17 - $35 | These brands offer a good balance of quality and value. They are designed to meet or exceed original specifications and are a popular choice for DIY and professional repairs. |
Pro Tip: Consider Replacing the Blower Motor
If your resistor has failed, it could be due to an old blower motor drawing too much electrical current, which overheats the resistor. If your van has high mileage or if the fan was making noise before it failed, it's wise to consider replacing the blower motor at the same time. This can prevent the new resistor from failing prematurely.
Installation Overview
Replacing the blower motor resistor on a 1996-2000 Caravan is a straightforward job that most owners can do themselves. On these models, the resistor is located on the passenger side, under the hood, on the firewall. It is often tucked near the strut tower, and access can be tight. The part is typically held in by clips, not screws, and can be pried out. Some owners find it easier to remove the windshield wiper assembly for better access, but it's not always necessary.
Frequently Asked Questions
Why do my fan speeds only work on high?
This is the classic symptom of a failed blower motor resistor. The 'high' setting is wired to bypass the resistor, sending full power directly to the fan motor. The lower speeds all rely on the resistor to reduce the current, so when it burns out, those speeds stop working.
Is an OEM resistor better than an aftermarket one for my Caravan?
For this specific part and vehicle generation, a quality aftermarket resistor is a perfectly acceptable and much more cost-effective choice. Brands like Dorman, Standard, and Four Seasons are established and reliable. The original Mopar parts are often significantly more expensive without offering a noticeable performance or longevity benefit for this component.
My new resistor burned out after only a few months. What happened?
A repeat failure is almost always caused by an aging blower motor. As the motor gets old, it works harder and draws more amperage to spin. This excess current overloads the new resistor, causing it to overheat and fail quickly. If you're on your second resistor, you should replace the blower motor as well.
Do I need any special tools for this job?
No special tools are usually required. You may need a flathead screwdriver or a small pry tool to release the clips holding the resistor in place. If the electrical connector is damaged, you will need wire strippers and crimpers to install a new pigtail connector.
Technical Specifications
OEM Part Numbers: 4720278 68004241AA 4677180
5-pin connector
We Have This Part in Stock
The information in this article is provided for general reference and educational purposes only. Vehicle specifications, procedures, and part compatibility can vary by production date, trim level, and region. Always consult your vehicle's factory service manual and verify part numbers before purchasing or performing repairs. Safety-critical components such as airbags, seat belts, and braking systems should be installed by a qualified professional.
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