I've got a similar problem on my 04 ST. Blower motor stopped. Just quit. Had some rain the night before and went out in the AM and nada.
This is manual climate but it has rear air.
Oh, the rear air works still but the front air does not at all.
Well spent a half day doing diagnostics in the 04 ford shop manual E F G testing... Did "I" step testing today but never came to firm belief on what was wrong. when I discovered the Auxilliary relay box below the air filter box. :smack: I Finally swapped a relay (2 actually)
Did not see anywhere in the owners guide or ford book there was a second box or relay!
I switched the blower relay on the main box with the other one on the aux box and to my surprise, had the 3 lower speeds! I says to self, just order 2 relays and replace them both!
I ordered them and got them a week later, got around to the fix Saturday and plugged them in. Tested briefly by turning the key to run and moving the switch. It all worked! About 1n hour later got in the ST to go to town and no air at all.
Spent a couple hours more re-evaluating the testing and more time looking for a diagram online! Still nada. Found a ford diagram and ordered it but won't be here till next week.
Relays okay, Fuses Okay, Resistor OK, Blower motor OK,
The testing in the book points to a relay but its good, I have 4 of them now that interchange and have tried them every way possible!
I tested the interior switches last week and they were in tolerance from the book specs.
What the heck?
Anyone got ideas? to try Is the lower relay for the hi blower? Seems like it makes sense that is the case.
Other notes. The relay up top, the power block looks like it has been hot under the relay. I took the power block out 2 weeks ago and the wiring underneath is all super! no apparent loose connections to the 40 fuse or relay. Tested continuity and all good for these circuits.
Took the aux panel off today and it looks great underneath as well.
