Hi, a quick report here: I had just replaced the blower resistor a few
months ago. The part at the dealer cost me $25. Now just few months
later the thing is broken again. It's a bit expensive to buy a new
resistor block every few months.

So, I repaired it myself this time. It's really easy! Pull the block
out from wherever it is (it's easy on my 99 RAM Van). Remove the metal
cover by bending the four legs straight so you can pull the cover off.
Now you have access to the resistors. You'll see 4 resistors, 3 of them
are just wire coiled up. The one that's blown is probably the fourth
one that's not just a coil of wire. You can verify that with an Ohm-
meter.

Pull that one off carefully so that you don't break off the wire but
pull it out as a whole. That way you'll have the holes for your
replacement to go in.

Now you build your own resistor from a few inch of wire that you coil
up on a Philips screwdriver shaft. I used the type of wire that I had
to bind flowers. But any wire that's as thin or a tad bit thinner than
the thinnest wire in the array will do. Don't do it too thin or it will
blow. No plastic insulation is better or else it will stink when it
gets hot.

Target a resistance of about 3 Ohm for that self made resistor and
stick it into the assembly. Put the metal lid back on its place,
make sure there are no shorts. Put it all back and try it out.

It worked for me.

regards,
-Gunther