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Take it apart and clean it out as much as you can. Cleaner ( like lysol spray?) may help. Take the blower motor out-that should be easy to get to-and clean out that cavity.
It is the resistor pack, not the switch, for the blower speed problem. See if you can take the glove box off or out. Look for the resistor-it is somewhere on the heater case, and easily replaced. Only one or two screws that hold it, and the electrical connector, and it's free.
A heater blower motor resistor is an electronic device with three or more progressive resistors that allow the heater blower motor to operate at slower speeds.
The highest speed of the heater blower motor
is not controlled by the resistor, so when the resistor fails, the fan
will often work on the highest speed setting, but not the lower speeds.
To resistor is generally located under the dashboard and under the hood, near the blower motor .
The resistor's electrical connector is disconnected, the resistor is
removed and the new resistor is installed. On some vehicles it may be
easily accessible, and on others it may take partial dashboard removal
to replace the resistor. Look under the hood, generally the wiring for the Blower resistor is attached to the wiring to the blower motor itself It's inboard & below the motor, near the accumulator. You can see
it standing beside the passenger fender. it's the off-white connector
behind the L heater hose above the vacuum reservoir & the white
The heater blower is normally controlled by voltage sent to the blower via a resistor network.
In this case it seems that this unit also called the fan resistor is defective.
I assume that 4 is the position where the blower is running HIGH and in this position the blower is powered directly without using resistor for lowering the speed of the blower. In step 1 - 3 the blower is powered via the mentioned resistor network.
In my opinion the resistor network is defective.
Replace it !!!!.
From the scenario that you have just described; more than likely your blower motor resistor pack has failed. On the highest setting, the blower motor will have no resistance from the resistor pack allowing the motor to turn the fan at full speed; however, on the lower speeds, the different resistors are what create your different speeds by varying resistance in the electrical circuit.
I am guessing that you are referring to the blower motor not moving air till the highest setting? If that's the case, there is a blower motor resistor part that handles voltage for all lower speeds. You can usually change this part without too much trouble. They're usually priced very reasonable from the dealer. Once you have it in your hand, you can look for it screwed into the heater case.
Check on the outside/ under the hood. on the passenger side of the firewall there is a flat board whitish in color carfully pull that off and make sure all the connectors look clean this is the cheap way out.
The resistors are in circuit only on the lower fan speed settings.
On the highest speed setting, power is switched directly to the fan motor.
Check fan power supply fuses,
Check power is available to the fan when high speed selected.
If all above OK, apply power directly to the motor to verify fan motor runs- if it doesn't the motor may need replacement/repair.