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Wow Such Admin
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Just thought I'd make a short post about my experience doing the blower motor resistor. Just for reference, I did drill the holes as per the bulletin in the bottom of the car to try to keep this from happening as soon as I bought the car. At first my speed 1 and speed 2 of my fan were spotty and working on and off. Then after a couple weeks, all 3 speeds stopped working. I figured it was time to jump in to replacing the resistor. I ordered all the resistors from this thread:

http://www.lotustalk.com/forums/f313/diy-blower-motor-resistor-pack-replacement-78524/

I used those, which was much cheaper than doing the fix Lotus made for it. I made a square plate to mount the resistors on. (I wish I would have taken pictures of my plate and resistors but for some reason I didn't). Taking the clam off was pretty simple, a friend and I had it off in about 40-45 minutes.







It was filthy under the hvac box. While doing all of this, I cleaned all of that crap out and wiped it clean in there. The most difficult part of this is indeed getting the box out and back in. It was kind of a pain, but with enough work came out just like it should. I actually mounted my resistors under the driver side access panel for future access and just ran the wires down to the fan. I did replace the drier as everyone should if the a/c system is opened. Radiator was not leaking, so I decided not to replace it yet. All in all, the job wasn't that bad.
 

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I'm in the process of pulling the front clam to replace my radiator. Good time to do the resistor pack replacement also. Thanks for the reminder.

JT
 

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Man I found this job to be quite terrible. The worst part for me was getting the box in and out as you said. However there are alot of other painful steps as well. I did learn how to evacuate and recharge AC in the process though.
 

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I'm in the process of pulling the front clam to replace my radiator. Good time to do the resistor pack replacement also. Thanks for the reminder.

JT
Since I am in complaining mode:

Taking the clam off is about 5% of the resistor pack job. You probably already know but fixing this will easily double or tripple your radiator replacement time. It is a good idea to do them together though because you will be flushing your coolant.
 

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Wow Such Admin
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Discussion Starter #5
Man I found this job to be quite terrible. The worst part for me was getting the box in and out as you said. However there are alot of other painful steps as well. I did learn how to evacuate and recharge AC in the process though.
Having a a/c machine at work ftw. Didn't have to worry about any of that. Recovered all the refrigerant at work, did the job, and recharged it back at work. I didn't think the job was all that difficult, but then again, I used to work on cars for a living.

Since I am in complaining mode:

Taking the clam off is about 5% of the resistor pack job. You probably already know but fixing this will easily double or tripple your radiator replacement time. It is a good idea to do them together though because you will be flushing your coolant.
I actually didn't end up having to drain really any of the coolant. When I pulled the heater hoses off, I clamped them off. Barely had to top off any coolant when I was done with the whole job.
 

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I didnt think it was super difficult either but a real PITA. I think if you are a former mechanic and have access to an AC machine you are starting from a much better place than a typical shade tree guy. I was just trying to give a little counter caution to some.

Ive seen a few posts about changing the resistor pack "while your in there". I just want everyone to be clear, it is a bit more involved than one would think.
 

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Wow Such Admin
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I didnt think it was super difficult either but a real PITA. I think if you are a former mechanic and have access to an AC machine you are starting from a much better place than a typical shade tree guy. I was just trying to give a little counter caution to some.

Ive seen a few posts about changing the resistor pack "while your in there". I just want everyone to be clear, it is a bit more involved than one would think.
Oh, it was definitely a pain. I'll admit that. That stupid box does NOT want to come out of there.
 

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2005 Lotus Elise; 2007 Lotus Exige S; 2012 Porsche 991S
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Sorry to revive an old thread but how in the hell does that HVAC box come out of there? I have everything apart but can't seem to get it out. Any tips?
 
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