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This is a common problem. I have lived with mine like this since last fall. The cheap, home, solution was posted by an Aussie at that time. It is a blown resistor. I will post the solution later when I get home.
 

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yep same problem here...
unscrew the resistor buy some resistance-wire and replace the broken one which is ussually #1 because it the thinnest.

Frank
 

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The Aussie with the fix was probably me. I had the exact same
symptoms a few months ago. Fan speeds 1 and 2 not working
and fan speeds 3 and 4 working fine. You will find that if you
have a look under the dash on the passenger side (removing
the plastic cover) you'll see the blower and behind that, a
small black piece of plastic with a few wires on it screwed into
the metal. If you unscrew this you'll see 4 wire coils and the
second one of the four will be broken. Cut this one out
without damaging the others and go down to a local
electronics shop and get a 0.47 Ohm, 5 Watt ceramic resistor.
The easiest way to fit the resistor is to crimp the wires onto
the metal posts where the blown coil was, making sure the
wire doesn't touch any of the other coils. This fix is still working
fine for me and I can't tell any difference in fan speeds than
compared with the stock resistors.

Mike
 
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Yes, here is the detailed solution that Mykl posted before:

Heather fan resistor
It is the heater fan resistor, I had exactly the same problem
last week. It is due to the second resistor of the four in series
blowing. It will probably not get worse unless another one
blows, but the 2nd seems to be the weakest one. You can
either get one from a wreaker, dealer or fix it yourself. Over
here in Australia the dealer wanted about US$60 for one, the
wreaker wanted US$20, and I fixed it for US$0.15. What you
need to do is pull the black plastic covering off the bottom
of the dash under the glovebox, you'll see some wires going
into a black plastic piece that's screwed into the metal near the
fire wall behind the blower motor (gold coloured on my car).
Unscrew this and you'll see 4 coils, one of which will be broken.
You need to carefully pull or cut this one out and replace it
with a 0.47 ohm, 5 watt resistor from an electronics shop.
 

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Discussion Starter #8 (Edited)
Found Broken # 2 Coil

Right on the money! A snapshot of the part is available in the following link. Now I'll just need to get the resistor and install it.

Thanks,
jSTeele

I tried the link and Yahoo will not allow the picture to be displayed. I'll put it on the web site then put a link to it later. :mad:

Here is the updated link to the picture. Please go all the way down the page and the picture is in the right hand corner.

http://www.geocities.com/freddjohn/Virus_Hoax.html
 

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Discussion Starter #10
Fixed Link

Had to put the picture on the web site. Yahoo won't allow picture lifting anymore. Go to the bottom of the page and a picture is in the right hand corner. It's not very big, but I didn't have a lot of room either without throwing together another page.

Unfortunately the detail is hard to see, but the broken coil is visible when pic is regular size.

Broken #2 Coil Picture

jSTeele
 

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Discussion Starter #13
Link/Pictures

I'll post a new thread containing the pictures and procedure involved with fixing the fan selector switch problem.

(Note the link in a previous post will work, but will not have the picture in the bottom right hand corner any longer. Created new page for pictures.)

jSTeele
 

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i got this problem as well , any pics?
 
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