How do you replace a blower resistor on a 1998 Chevy Malibu?

This has been discussed many times here before, and I thought I would bring all of the information together in a "how-to." I have personally replaced this part with one purchased for $20-25 (Local Autostore, I.E. CarQuest, Autozone, Discount Auto) . The repair will take about 30 mins. to one hour to complete.

Problem: HVAC Blower motor only works on fan settings 3, 4 & 5.

Reason: Blower Motor Resistor is bad, and needs to be replaced.

Affected Model Years: 1997, 1998, 1999, 2000, 2001

Permanent Fix:

You will need: 1/4" Socket set -or- a 3/8" set with a universal joint . 1/4 " prefered & universal with 5.5 or 6mm socket will work

1. Remove the plastic cover from the underside of the passenger dash under the Glove compartment, held in by four bolts. Note how the two air ducts on the left and top are connected, and how the other plastic cover piece is connected to the piece you are removing. This is helpful when you go to reinstall it.

1a. I found it helpful to remove the glove box. 7 easy screws and I had access to everything behind it and could see what I was doing.

2. Slide the Control Module to the right and pull it down carefully. Push it to the right being careful not to damage the wires.

2a. Control module on some cars is on the right and fit in a slot on the top of the module. This can remain where it is.

3. Remove the blower motor power cable located on the forward side of the blower near the firewall. Not necessary on some models.

4. Remove the jumper cable link to the blower motor resistor located on the resistor near the forward side of the blower.

5. Remove the blower motor held in place with three 7mm bolts. You may not need to do this, but it helps give you some room to work. It will also let see the blower motor resistor before proceeding. Not necessary on some models. Resistor is just ahead of the blower motor and removing the motor doesn't give you any more room.

6. Remove the two 5.5 mm bolts that hold the green (or blue) blower motor resistor (This will be the item you disconnect the cable from in step 4).

7. Install the new resistor using the two retained bolts. The improved part will be longer than the original, and will be black in color. Don't forget the soft gasket on the resistor.

8. Re-install the blower motor using the three retained bolts, if you removed it originally.

9. Re-connect the blower motor power, and the resistor jumper.

10. Test the blower fan settings prior to putting the dash back together.

11. Align and push the Control Module up into the slot and slide it back to the left.

11a. You will need to tie a piece of string around the hose like duct to guide it into the plastic cover on replacing, IF you have not removed the glove box.

12. Re-install the plastic cover using four retained bolts. This is where it helped to pay attention to the ducts and the other cover when removing.

*Note: on the 2.4L '98 Malibu, in step #1, there are only 3 bolts & 1 duct. Steps 2 & 5 are not necessary. I recommend buying the new resistor first, or looking at a new one so you know what you're looking for.