Speeds 4 and 5 stopped working shortly after I bought the truck 2 years ago. The blower stopped working completely about a month ago. Since then I've done the following:

1. Replaced resistor. The plug on the old resistor melted, so I had to splice a new plug in. All 7 wires were spliced accordingly. I plugged the new resistor into the blower, but no go.

2. Figured maybe the blower went, too, so I bought a new one. Plugged the new blower in, but still no go.

3. Checked all fuses related to the blower and HVAC. Every fuse is intact. Can a 40W fuse look intact but still be bad?

At this point I'm out of ideas and going crazy. Any suggestions would be greatly appreciated. Could it possibly be the ****/switch on the dash has gone bad?

 

Considering what you have already done,I would suspect the HVAC control panel itself...It simply unplugs with 2 connectors once the dash fascia is removed.

You could also test one from a friends truck of same model year. Literally 5 minutes to remove.

I believe the 03' to 06' models were much more prone to failure than the earlier 99' to 02' versions.

E-bay or a wrecking yard could be a good option

 

Bought a voltmeter. Pulled the climate control module out of the dash. Tested the incoming black plug and I have power coming to the module. I also tested the resistance of all five speeds on the module. Had a 000 (good) reading on all, including the OFF position. So I plugged the module back in and tested the newly spliced in plug to the resistor. I have power coming through the G terminal (terminals A-F have nothing but I think that's irrelevant). Now, when I plug it into the new resistor and test the plug that attaches to the blower motor, I get nothing. I guessed that this new resistor I installed is either faulty right from the box or I fried it somehow when I plugged it in. So I bought another new resistor.

Something I should mention is that when I found I had power on the G terminal, I had the fan speed **** in the OFF position. Should I be getting power at all? I don't want to plug in the 2nd new resistor and have the same thing happen as the 1st one.

 

67Motorcat, thank you for the suggestions. Considering the part from O'Reillys or NAPA is $115 plus a $200 core charge , the junkyard is looking like a more affordable option.