Blower works intermittant when on auto or manual.

Since it is intermittent. Check plugs to the controller and blower.

in review
the fan speed resistor is new
you bench tested the blower motor
12 volts test ..only runs it at full speed
if cabin filer want changed the blower motor would run hotter

could be the motor brushes or bush/motor bearing when slowed
you might want to inspect the brushes and clean the dust out of the motor
if no better
does that have climate control ?
might be the fan switch itself or the earth isnt so good

Check engine temperature, fan operation and thermostat.
Also check inside blower operation. If intermittent, then check and/or change the blower motor.

may be the blower relay ???

There is a thermal fuse inside the air duct. It is located behind the passenger glove compartment. tilt the glove door down and remove and look in. You will see a conector with about 4 to 5 wires. usually held on with two screws remove and inspect. The thermal fuse that runs between the coils will be open. Bypass it at your own risk or buy a new one from dealership or auto wrecker. May meen you fan is running too slow also and not blowing enuf cool air past it.

First check fuses, then test blower motor, Last Temp control switch

Hi , this sounds like the hearter resistor has become faulty , other symptoms include the battery going flat due to the blowers opperating even when the ignition is switched off, hope this is of some help , regards mark .

check the blower resistor

pull motor ,check for burned wires onfan and bak of fan speed switch,fan could be the problem un hook fan and conect directley to 12 volts and see if varibles exsist,if so replace fan motor/look for a fan resister if all the other things check out

Most likely it does, if you can hit the motor and it will run. I can't say for sure but you might want to chk. to see if you got a heater blower motor resister. There located (if its got one) around the heater motor and it controls blower speeds, might be worth checking out.