Hi all,
First off, big thanks to everyone who contributes on these forums. I was able to search through here, diagnose my issue, and complete the repair thanks to several previous threads.
Issue: The blower fan stopped working on our 2011 Subaru Legacy and would not activate at any speed.
Steps taken:
1. Checked and replaced cabin air filter. It was filthy but nothing was blocking the fan from spinning. (Filter/debris not the issue)
2. Visually checked the fuses for the blower fan, the AC, and the cigarette lighter. None appeared to be blown.
3. Removed blower motor & fan. Hooked it up to the car battery with test leads and the fan turned on immediately. (Blower motor not the issue)
4. Checked the blower motor resistor. It appeared to be rusting in some spots on both the resistor and the connectors. Continuity test with a multimeter appeared to check out but I replaced it anyway. I didn't suspect this was the issue because most posts indicated the fan should still work on the highest setting, bypassing the resistor altogether. (Blower motor resistor not the issue)
5. Rechecked all fuses with a test light. All appeared to functioning properly. (Fuses not the issue)
6. Checked blower motor resistor and blower motor connections for power with the test light and multimeter. I did not get readings using either and suspected it was either the heater control switch or something with a wiring or relay. (Power not getting to the blower motor!)
Upon further inspection, I could hear a relay behind the glove box switching on and off as I turned the knob for the fan speed. I also felt the motor and it quickly turned on and off as well. I decided to check the control switch and thought perhaps the connection was loose. A picture of the relay is below. I removed the side panel on the passenger side for better access to it but did not remove the relay.
I used a trim removal tool to take apart the dash and get access to the control switch. Pictures are below showing where each of the 6 clips are located if that's helpful for anyone.
When I tried to remove the large connector from control switch, the connection on the back of the switch broke off completely. Once I removed the two screws holding the switch in, disconnected the smaller connector for the hazard lights and vent selection, and gently pulled the control switch out (two remaining clips near the bottom hold it in), I noticed melted plastic around the connection for the fan speed selector. Pics are below. (Bad heater control switch!)
The replacement switch is over $300 from a Subaru dealer but I was able to find a replacement from a reputable salvage yard for $75. Some were cheaper but this switch came from a low-milage 2014 wreck.
Put in the "new" control switch today and the fan started right up and worked on all speeds!
I do have one question; based on the pictures, is the connector anything to be concerned about? It took some heat damage from the burned out control switch connection.
Thanks again to everyone who posts and comments on threads. Great community here to search and learn about DIY repairs!
