Years ago I modified the blower housing to accept a 2001 (I think) blower motor and resistor since mine failed and the new ones were very expensive (at the time). This will only apply to factory AC cars. There are other options now but another member requested that I post a pic for those that might be interested. If you choose to attempt it, you'll need the blower motor, resistor, squirrel cage, and as much wiring (mainly for the connectors) as you can reasonably grab from a 2001-05 Taurus with manual (knobs) HVAC controls. The Taurus is also ground side switched for blower speed, the Maverick is power side switched so the Maverick wiring will need to be altered or you can use most of the Taurus harness. I used the power feed from the Maverick HVAC switch to turn it on so that off on the Maverick switch is off on the motor as well. I also added a high speed relay for high speed to reduce the heat in the switch. You will have to modify the housing to fit the bigger squirrel cage, I used an angle grinder with a sanding head to remove enough material from inside the blower housing. This will open a small triagular hole at one point but is easily filled by taping over the inside of the hole and applying a thin layer of epoxy in the hole from the outside. Remove the tape when the epoxy cures. Remove the Taurus motor from the housing by loosening the T30 torx screw and gently working the plastic base off. I made a bracket to go around the motor and welded L-shaped tabs on a piece of exhaust tubing to hold the motor. I welded bolts to the tabs to make fixed studs that allowed the mounting holes to be utilized. Instead of attaching the motor directly to the bracket, I used a large band clamp (from a diesel boost hose, 3" if memory serves) to attach the fabbed motor bracket. This allows some depth and rotational adjustment since I wasn't sure of the placement of the connector for the motor. You'll also need to open the hole up a little for the resistor since the Taurus one is bigger. It HAS to be in the airstream. It won't work otherwise, it will overheat and burn out the thermal limiter. This arrangement has been in my car for 10+ years with regular use (I drive the car at least a couple of times a week during all seasons here in Georgia) and I haven't touched it since installing the relay on the high speed. I happened to have some of the parts at the time so this was very cost effective for me at the time but now with other options might not be as practical especially for those who aren't comfortable with wiring modifications and enhancements. But if you are, I say go for it.
