Heater Resistor Upgrade

[Rfkdemon]

I have just replaced the heater resistor for the 2nd time on my 2019 T6, never had a vehicle go through so many in such a short time.

Has anyone upgraded the OEM resistor as this seems to be a super common issue?

This time it appeared to be slightly corroded, has anyone else observed this and is this a contributory factor to the failure?

I noticed that someone on here changed theirs for a PWM motor controller so maybe that is the solution instead of the resistor becoming a service part every two years?

Mat

 

[Snowy1957]

Afternoon Mat.
Did you have any luck finding a solution to the resistor problem, resistor upgrade etc. ?
PWM motor controller ? Not sure what this is,sorry.
I’m having similar problems like yourself& VW are recommending a blower motor replacement at a hefty £1200+ to potentially rectify the problem !?
Any help would be greatly appreciated on this issue Mat.
Regards,
Brian

 

[Dellmassive]

Just replaced mine for the secend time.

2018 van , first one done at 3years, 35k miles.

Now again at year 6 with 96k miles...

And yes, slightly corroded from damp air over the winters is assume.

An absolute pig of a job.

Made easier with a mini ratchet spanner.


...



...

 

[JumpShip]

Why are they so common on the t6 ?
Our t5 1 is 15 years old and is still on its first factory resistor .

 

[Dellmassive]

Who knows... My vans are set to speed#1 all the time, which is the hardest on the resistor.

Coupling that with a cold morning engine start, causes lower voltage and higher current... They caused the thermal fuse to pop.

I've seen people re side the thermal fuse....... But I just replaced the unit with a cheaper patent part.

I think it's the same as everything these days,, ... Every year things seen to manufacturer cheaper with less quality.

Prime example T5, T5.1, T6, T6 1 ...... While reach version is outwardly better than the previous,. You can notice where they have cut corners and made bits cheaper.

 

[JumpShip]

Yeah I'm happy to have a footrest , 2 reverse lights and no adblue ....but thats about it for the positives of running an older van

 

[The Flying Scotsman]

Afternoon Mat.
Did you have any luck finding a solution to the resistor problem, resistor upgrade etc. ?
PWM motor controller ? Not sure what this is,sorry.
I’m having similar problems like yourself& VW are recommending a blower motor replacement at a hefty £1200+ to potentially rectify the problem !?
Any help would be greatly appreciated on this issue Mat.
Regards,
Brian

Where the hell are they getting £1200 to supply and fit a new blower motor when they cost £24 ?

Pardon our interruption...

I replaced the one on my pals T5.1 was a pretty simple job to do.
He paid £24 all in as I fitted it for free.
Incidentally I’m needing to replace the resistor in my T5.1 again.
The 2nd time in about 15 years and 181k miles.

 

[FWhite]

Where the hell are they getting £1200 to supply and fit a new blower motor when they cost £24 ?

Pardon our interruption...

I replaced the one on my pals T5.1 was a pretty simple job to do.
He paid £24 all in as I fitted it for free.
Incidentally I’m needing to replace the resistor in my T5.1 again.
The 2nd time in about 15 years and 181k miles.

Just curious,
What is this resistor for , exactly?
Where is it phisically located?

 

[The Flying Scotsman]

Just curious,
What is this resistor for , exactly?
Where is it phisically located?

If you have a look at post 3 on this thread by Delmassive it shows you the resistor and how to fit it.
When it goes your fan will only work on setting 4.
I didn’t think it was too bad to fit.
Didn’t take me long
It’s up under the dash passenger side

 

[DXX]

Just curious,
What is this resistor for , exactly?
Where is it phisically located?

It’s a group of resistors to regulate the fan speed, the reliability issue is the thermal fuse blows on setting 1. Avoid setting 1 and it’s not an issue.

Search

www.t6forum.com

This has nothing to do with Glow plug 2 by the way.

 

[FWhite]

I understand. Fan speed regulation done the ancient way. Simple and usually reliable, while energy wasting.

I now understand why someone mentioned a PWM motor regulator upgrade, that would be the "modern" way.

Thanks for the info, I will then avoid position 1 , especially in the summer.

 

[Dellmassive]

The thermal fuse is inline with the fan blower, .. when the fuse goes out knocks out all three lower speeds.

 

[Lubrown]

Yeah I'm happy to have a footrest , 2 reverse lights and no adblue ....but thats about it for the positives of running an older van

Still appreciate my 5.1 for various reasons and it’s still on the original fan resistor despite my fan living on setting 1 (hadn’t heard this was apparently an issue before).

The only fan issue I have is noise which I assume is due to worn bearings. Replacement I spotted was £80 for the entire fan unit to OE spec. Looks a simple enough DIY job. If it doesn’t come with one I’ll swap the existing resistor straight into the new unit with a smug grin

 

[DXX]

Still appreciate my 5.1 for various reasons and it’s still on the original fan resistor despite my fan living on setting 1 (hadn’t heard this was apparently an issue before).

The only fan issue I have is noise which I assume is due to worn bearings. Replacement I spotted was £80 for the entire fan unit to OE spec. Looks a simple enough DIY job. If it doesn’t come with one I’ll swap the existing resistor straight into the new unit with a smug grin

I’d check for debris touching the fan impeller first, the grill in the scuttle is coarse.

 

[Lubrown]

I’c check for debris touching the fan impeller first, the grill in the scuttle is coarse.

Thanks for the suggestion but I checked all that recently. I was soundproofing the scuttle tray and areas behind the dash so had a good look around the fan. Also changed the cabin filter and peered into it then. Got a couple of little leaves out but nothing excessive as I change the filter annually and always check.

It’s a real rumble too when it gets going. If I turn the fan off and on again it’s quiet for a minute or two then ramps up.

 

[Gazwari]

Hi @Dellmassive - I just had a go at this at lunchtime on my T6, and yes - tight and fiddly job which I failed in the time I had! I managed to get the resistor undone but had left the cable on - thinking it would be easier to pull out once outside, but with the carpet there too, I didn't find I could manoeuvre the resistor out.

After many failed attempts whilst bolts still out, I didn't have enough leverage so put the bolts back in and continued trying.. Just can't seem to free it up and manage the finger pain at same time!

Any good tips?

 

[Dellmassive]

Hi @Dellmassive - I just had a go at this at lunchtime on my T6, and yes - tight and fiddly job which I failed in the time I had! I managed to get the resistor undone but had left the cable on - thinking it would be easier to pull out once outside, but with the carpet there too, I didn't find I could manoeuvre the resistor out.

After many failed attempts whilst bolts still out, I didn't have enough leverage so put the bolts back in and continued trying.. Just can't seem to free it up and manage the finger pain at same time!

Any good tips?

its a PITA job with the carpet, thats for sure.

i tried pulling the carpet down, but it mean stripping more trim off.

in the end i done it with brut force, bending the old old to get it out.

 

[Gazwari]

its a PITA job with the carpet, thats for sure.

i tried pulling the carpet down, but it mean stripping more trim off.

in the end i done it with brut force, bending the old old to get it out.

Thanks for the quick reply - perhaps I'll go with the bend it option too! Cheers!

 

[Snowy1957]

Thanks for the quick reply - perhaps I'll go with the bend it option too! Cheers!

With the bolts in place, grip the connector on the outer edges & squeeze….then slowly wiggle the connector from side to side whilst keeping pressure on the connector & pulling it out at the same time (it will come)
Then remove the 2 bolts & take out the resistor
PS.
I’ve just replaced the thermal fuse on my resistor for less than £1 & mines working fine again, if you can solder then it’s really easy
If you can’t, ask someone that can, it takes minutes once the resistor is out of the van.
Just be mindful when soldering it into place not to overheat the NEW fuse, I used a pliers as a heatsink when soldering the new fuse in place (I bought mine from eBay, but i didn’t use the crimps I ordered)
Good luck.

 

[Gazwari]

With the bolts in place, grip the connector on the outer edges & squeeze….then slowly wiggle the connector from side to side whilst keeping pressure on the connector & pulling it out at the same time (it will come)
Then remove the 2 bolts & take out the resistor
PS.
I’ve just replaced the thermal fuse on my resistor for less than £1 & mines working fine again, if you can solder then it’s really easy
If you can’t, ask someone that can, it takes minutes once the resistor is out of the van.
Just be mindful when soldering it into place not to overheat the NEW fuse, I used a pliers as a heatsink when soldering the new fuse in place (I bought mine from eBay, but i didn’t use the crimps I ordered)
Good luck.

View attachment 315012

Thanks! I’ll take the tips on board and give it another go before unbolting - when I won’t have already gone through a ton of finger pain trying to do it unbolted!