Replacing Gen 4 Heater & A/C Blower Motor

From Taurus Car Club Maintenance and Modification Wiki

Replacing the Heater & A/C Blower Motor is fairly easy. This procedure was done on a 2002 Taurus SEL with electronic environmental controls, but will work with the manual controls as well.

All blower motors are manufactured by SIEMENS AUTOMOTIVE, Part Number PM9197. I purchased a "Motorcraft" replacement, and it had a Siemens label on the part. The original was also a Siemens.

This is a detailed step by step procedure:

1. Remove all contents from glove box. Close the glove box.

2. Use a 7mm socket and remove 3 screws holding the glove box in place.

3. Open the glove box, and turn counter clockwise to remove it.

4. Using an automotive interior grommet tool (or a straight screwdriver) remove the 2 grommets that hold the black trim piece that covers the A/C plenum.

5. Disconnect the wiring harness from the blower and the relay box.

6. Use an 8mm socket and remove 3 screws holding the blower motor in place.

7. The whole blower motor assembly will then drop down. You may have to “persuade” it to come out.

8. The new blower motor does NOT come with the bird cage (fan assembly), so you will need to remove it from the old motor assembly. Remove the retaining clamp on the top of the shaft. This can be done with a pair of pliers.

9. The old shaft may be rusty. Use WD40 or suitable alternative to help in getting the blower wheel off.

10. Using a large open end wrench, wedge it up into the bottom of the blower wheel, between the wheel and the motor. Apply some pressure, and spin the wheel. Eventually, it will come off.

11. On the new motor, apply the supplied foam rubber gasket to the knife edge seal area.

12. Slide the blower wheel onto the shaft, and lock in place with supplied new clamp. Use a 10mm socket on the top of the clamp, and a hammer to seat into place.

13. Replace the blower motor in the plenum in the car. Once again, you may have to persuade it to get into the hole.

14. Use an 8mm socket and replace the 3 screws holding the blower motor in place.

15. Reinstall the wiring harness, and test to make sure it is working.

16. Reinstall the black trim piece that covers the A/C plenum.

17. Put the glove box back in place, and close the glove box.

18. Use a 7mm socket and replace the 3 screws holding the glove box in place.

19. Open the glove box, and put all the stuff back in.

20. Take your car for a test drive, and enjoy the functional again heater & A/C!!!