How to Change the Blower Resistor Pack on a 2002 Pontiac Grand Prixby Derek Powlison
In the heat of summer, or the frigid depths of winter, blower motor failures frustrate numerous owners of 2002 Pontiac Grand Prixs. Blower resistor packs cause most of the failures. Rarely does the blower motor itself fail.
The blower resistor pack drops the voltage to the blower motor, reducing the speed of the fan motor at lower speed settings. Less power equals less airflow. Restricting the voltage creates heat in the resistor pack, and over time, the resistor burns. A burnt resistor often loses first one speed, then another, progressing as the damage spreads across a cooked circuit board until the blower motor no longer operates at all.
Removing the Blower Resistor Pack on a 2002 Pontiac Grand Prix
Open the passenger door. Get down on your knees, and look up above where the passenger feet go, directly under the glove box on your 2002 Grand Prix. There is a cardboard reinforced felt sound damper held in by plastic retainers. Gently pry the plastic retainer clips, being careful to not damage them. Remove the sound damper.
Pull the carpet down and away from the firewall, revealing the sound matting underneath. Looking at the bottom of the black heater case, the blower motor is the most obvious feature. The blower motor is bolted to the case, is round, and juts out like a small black can. Just ahead of this, close to the firewall, is the blower resistor, which is rectangular in shape and had a plug with several wires going into it.
Cut two incisions into the insulating mat under the carpet using your knife or box cutter, starting about 1 inch on the outside edge of either side the blower motor resistor. Cut down several inches to make a flap of the sound insulation. Pull the flap down to provide more access to remove the blower resistor pack.
Pull the gray safety retaining clip out of the connector to the blower motor resistor. Once this is free, unplug the blower motor resistor pack connector.
Remove the two obvious screws closest to you retaining the blower motor resistor pack using the socket and ratchet. Closer to the firewall and hidden behind the connector is a third screw. It does not need removal. Loosen this hidden screw approximately two turns without removing it.
Gently pull down and back on the blower resistor pack, rocking gently side to side to slide the pack off of the screw that you loosened. Once it pops free, the blower resistor pack will pull straight down and out for complete removal from your 2002 Grand Prix. If you inspect it, it is usually obvious where the resistor has burned and failed.
Installing the Blower Resistor Pack on a 2002 Pontiac Grand Prix
Push the blower motor resistor straight up into position. The connector faces down, and the side with two closed bolt holes faces toward you. The slotted hole side will face towards the firewall, where the screw that was partially removed is still installed. Slide the resistor into place.
Install the two screws closest to you, and tighten the hidden screw closest to the firewall.
Reinstall the electrical plug, and reinsert the gray positive retainer clip to prevent it from popping free. Turn on the key, and verify that the blower motor now works on all speeds. Remove the key when you're done.
Flip the flap of sound insulation back into place, and push the carpeting back up again.
Reinstall the felt covered cardboard sound insulator, and replace the push pins that hold it in place.
Things You'll Need
- Flat-head screwdriver or small pry bar
- Box cutter or razor knife
- 5.5mm or 7/32 inch socket, 1/4 inch drive
- 1/4 inch drive flexible extension or 1/4 inch universal and 3 inch extension
- 1/4 inch ratchet handle
- New blower resistor pack
Derek Powlison has over 13 years experience in the automotive aftermarket industry and has written automotive and business articles since 2007. He is an ASE-certified Master Automotive Technician and service writer.