Question about 2001 Dodge Caravan

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I'm having some of the same problems

I'm having some of the same issues with my 2001 Caravan. Also, the hands on my instrument panel (spedometer, tach, gas gauge) all go crazy from time to time, flipping back and forth with lights flickering. My air conditioner/heater blower only works on high and driver and passenger windows do not open. Did you ever find out what was wrong?

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I have replaced the same resistor pack on my 2001 Caravan twice.

It is located behind the glove compartment.
Just empty the compartment, release the stops at the top of the glove box, and the whole compartment will swing down.
The motor control resistor pack is the item on the heater fan bulkhead with 2 cable connectors.
Remove the 2 connectors, then remove the resistor assembly.

It went out this morning again! I took an old (bad) one and looked at the thermal fuse (metal bodied part looks like a capacitor) to get the rating.
For the record, The OEM part ID for the thermal fuse is MICROTEMP KKJAFW G4A15 TP 128c.
I researched Microtemp on the web and noticed that the part is no longer listed on Microtemp's website (if you can call it that).
The G4 series is apparently discontinued or just not listed.
It is supposed to be rated 10 amps, but I think it's more like 4 amps.
If 4 amps is indeed the rating, then it is borderline for a 12v DC motor.
The inductive load at turn on is probably what is blowing the thermal fuse.

DO NOT DESPAIR! I found a replacement thermal fuse at Radio Shack (of all places).
The R/S Part Number is 270-1322 and cost is $1.49 US. It has the same 128 Degree Centigrade rating as the original.
The Microtemp Part Number(s) is MNMABM G4A00 TF 128c (R/S Specification says it's 10 amps).
I was able to remove the steel shield from the assembly to get to the thermal fuse (use a permanent marker to reference the shield, plastic body, and PC board so re-assembly won't be confusing).
Snip the original leads just past the bends away from the fuse body.
Place the new fuse (with leads bent to fit in place). I put 2 thermal fuses in parallel so the DC motor startup current won't blow the 2 fuses.
Then solder in place. BE SURE TO USE A HEAT SINK BETWEEN THE SOLDER POINT AND THE FUSE BODY!
I used 2 alligator clips from R/S PN 270-0346 pack of 10 $2.79 US, to heat sink and hold in position while I soldered one side, then the other.
Before I re-assembled, I used an ohm meter to verify fuse continuity.
After I assembled the resistor pack, I re-installed on the Caravan, and viola it works!
I now have several spare assemblies (that I have repaired), and can replace if it happens again.
If you aren't very good at soldering, you might be able to find someone that can do this for you.
Keep the old assemblies so that you can repair them for future replacements.
Total cost for repair was $7.26 US. That was for 3 thermal fuses and the bag of 10 alligator clips.
Much better than $13 US for replacement assembly! Good luck, and I hope you get you fan problem sorted out!

Posted on Nov 14, 2008

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2001 blower (Air Or Heat) only operates on high
Behind the glove compartment right hand dash( just remove glove box liner) is a metal box of resistors which select through the Heater /AC switch called the heater control unit. Inside there is a thermal control diode/resistor
Small silver cylinder which can be replaced (or bypased because it's amperage rating is low)
Or Replace the whole heater control unit Plugs in
Billmol@msn.com

Posted on Sep 23, 2008

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