97 D1... as I am trying to cool car down I run a/c on highest fan speed #4. After 5-10 minutes, it cuts off and if I jiggle the **** for blower speed, it comes back on. Would this be a problem with a relay of sorts or something in the switch itself?

 

Similar issue happens with mine, but it only happens intermittently and regardless of fan speed. I'll be motoring along fine, AC blasting when all of a sudden the blower cuts off. No other electrical changes/symptoms. Then it comes back on again. Very random.

 

My 96 did that. Only on high. I read someplace if it gets overheated it cuts out then will start up again when it cools some. I used to just leave mine on 3 if it was hot.

 

very common on these trucks.....the contacts in the switch itself are either corroded , or they are actually burnt.....you have to pull the climate controls out of the dash to get the switch out of the caseing...then it is sometimes possible to disassemble the switch and clean it...you may want to start looking for a new/ used switch or climate control assy. If you're really lucky....a shot of WD-40 in the switch may cure it for a while

 

The blower motor uses a LOT of amperage, like 50 amps and the switch takes the abuse until it gets hot enough to melt. I had to replace mine as the parts inside the slide switch were melted beyond repair. I used a jumper wire for a bit and even that got extremely warm.

 

Have the same problem also... My '96 D1 a/c is awesome... but will cut out... It's almost second nature to tap the speed selector switch now... and now that the wife is driving it sometimes... it's almost a race. I'm gonna grab another switch from a local resource... in case it quits for good.

 

Replace the speed switch. I had that problem with mine. Problems gone.

 

Because of the fan's amp draw on high it warps the copper contact bars over time on the speed switch. I did two things with mine, flattened the copper contact bars, polished them and buttons contact with my handy dandy Dremel and filled any pits with silver solder. Ba da bing, ba da boom done. A little dielectric grease and it never cuts out on any speed. Been that way for seven years. YMMV (according to skill level).

 

Wait.....I thought this was normal.
Mine does it all the time.....Dim, Flicker.....Off.........

 

Smoke, Smolder, Ignite is in my experience...... I have no condenser fans anymore due to the relay catching fire.... oh yeah. I was cleaning up soot for about a week, plastic doesn't burn very efficiently behind a kick panel...... smoked the inside of the windshield to about a 5% shade. I love Rovers, never a dull moment. I had to laugh, I had nothing but a charcoal lump left of the ex-condenser fan relay. Ah, who needs condenser fans anyways.