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I have a 2005 Focus ZX4 S, the fan blower does not work in speeds 1 or 2 but work perfect in speeds 3 & 4.

Seems like the most common solution for a problem like this was to replace the resistor, (I tried that & nothing changed). In hindsight I should of did more diagnosis as it sounds like the resistor usually affect speeds 1, 2 & 3.

I am next going to try a new Fan Blower Switch.

Can anyone @FocusKnot describe how to remove the HVAC control cover to get at the switch? Or perhaps a video link. I'm think you probably just carefully pry the cover from the corners, but it's nice to hear it from someone who's already done this before.

Thanks in advance.
 

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Yep. Use a plastic trim tool and it pries right out.
In case anyone runs into a similar problem, I'll let you know what the issues was on my 2005 Focus, as it wasn't the usual resistor.

Symptoms: Blower Fan & A/C light did not function in speeds 1 or 2, but work fin on speed 3 & 4.

At first I thought it was the resistor, I changed it, nothing changed.

I then bought a Blower Fan Switch & changed that out & that fixed the problem.

I probably should of did a better diagnosis, (rather than just throw parts are it) but at first I was unsure how to remove the HVAC bezel to get at the switch so I went with the easy route by trying a new resistor. I later found out the switch was very easy to access by gently prying the HVAC bezel with a trim tool or putty knife.

The hardest part was just unplugging the harness from the old switch as Pin# 3 showed signs of being over heated (Slight melting a base of pin). It took a fair but of force, but I managed to remove the plug without doing any damage.

The new switch seemd to fix the issue, however I'm a bit concerned why the switch showed sins of being over heated. The fan blower seems to work fine, so I hope I didn't miss something that may cause the switch to over heat agan down the road.

Cheers
 
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