Blower
motor controller repair

The ACC II systems use a Darlington pair 30 amp power transistor in the fan
controller. ACC I systems use power resistors. If the fan
sticks on high speed, usually a shorted power transistor or an open resistor is
indicated, depending on which system is in place. Another failure ,mode
for the transistor is erratic blower motor operation, although I have also
experienced the same behavior with a bad blower motor. This write-up is for the
ACC II.
Things that can make the transistor fail: Insulation comes loose from the
inside of the evaporator, gets into the fan and the excess load blows the
transistor. Also, excess load due to water in the fan rotor cage (because of clogged
evaporator drains).
Be advised that the heat sink for the transistor is at +12 volts when the circuit is in use,
so be careful not to let the heat sink contact any chassis metal when the circuit is
powered. Normally it is inside the plastic evaporator housing, so it'd no
problem. However, if you actuate the system while it's removed from the
housing, you need to remember not to contact anything metal chassis with the
heatsink.
The ACC II fan controller is in the front of the evaporator housing on
earlier models (my 91, for sure). On the 94, it's closer to the blower
motor, more toward the top of the housing. Pictur
(of the 91).
To get to it on either the 91 or later cars, you have to remove the aquarium
cover, then remove the false bulkhead. Remove
the four T10 Torx screws that hold the controller in. Disconnect the
electrical connector and remove the unit. By the way, while you have the
unit out, reach inside the evaporator housing and find all the loose insulation
you can. Dry everything out thoroughly and use an aggressive rubber cement
to glue the insulation back in place.
As for the ACC II system's transistor, the Toshiba part number is 2SD1525.
Radio Shack used to be able to supply a replacement, but that is no longer
true. Many thanks to Glen McNeill for providing these alternate
sources for the Toshiba part: Findchips.com
is a good place to look for parts suppliers. Go there and enter 2SD1525. It will tell you that Newark
Electronics has them, and will provide a link to their site. I assume us average
one-sie two-sie consumers can purchase on line from Newark, but I'm not sure.
Glen got his from Audi Lab in Georgia. Go to the Audio Lab Web
site. This should take you directly to the shopping cart page for the
transistor. As of 11/94, cost is around $9.00; shipping is nearly as much
at $8.00 or so. While you're at it, order some heat sink compound
(grease): http://www.audiolabga.com/mal_cart/mal_cart.php?find=10-8109
(or just search for 10-8109).
Here's another possibility, provided by someone on the Saab bulletin board: http://search.mediagrif.com/bfparts2?/WebWizard/List/MemberID=SUMMITEL
And another, provided by Brian Spencer:
http://www.mcmelectronics.com
$9.10 for the transistor, he says.
If you didn't order some, go to Radio Shack to pick up a small tube of heat sink
compound (grease). You coat the back of the transistor with just a thin
layer of it so the transistor can
transfer its heat to the heat sink; it's important. This stuff is really
messy, as you will find out!
Pry off the cover. Remove the screw
that secures the transistor to the heat sink.
Remove the screw that secures the board.
You can now pry the board out of the housing (for the earlier cars, you'll have to release the
retaining clips on each side as you pry it out; for the later models, you'll
need to pry the connector loose from the housing - might be true of the earlier
ones as well). Note the orientation of the transistor, then unsolder the old
transistor, then bend the new transistor's
leads to match the original. Solder in the new (you'll
need a reasonably powerful iron). Before reassembly, smear a thin coat of
heat-conductive (heat sink) grease on the back surface of the transistor. Picture
Slide the board into the case, secure the transistor with its screw, secure the
board with its screw, then reinstall the cover. If you test the controller
before reinstalling it, be absolutely certain that the heat sink doesn't contact
any part of the metal chassis of the car (the heat sink is at + 12 volts when
the unit is operating, not at ground).
