I am basically having the same problem.

Last year, I had exactly the same problem as you describe. Kicking it also worked, but a bump in the road did too. So I opened the blower motor up.

The brushes on mine were very short and only weakly contacting the copper shaft of the motor. I replaced with vacuum cleaner brushes, but my fix is no longer working...darn, but no real surprise (I opened it again last week and noticed a broken brush wire, I resoldered, but it stopped working again).

So I am biting the bullet and buying a new blower motor. +/- $100 seems fair for a part that basically lasts 20 years. Getting the fan to attach to the motor looks interesting.

alec

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