Quote:
Originally Posted by BustedKnuckles
 That sounds very counter intuitive... If you replaced the whole assembly then there is no way to know for sure what the exact issue was in your case. Testing it just like you stated should prove the blower is ok. If you hook it up to a 12 volt and it runs nice and steady for a couple minutes then it should be fine. If there is an intermittent problem with either part, just plugging it back into the vehicle to run it doesn't prove anything. The fault could simply not be occurring at that time.
If OP's issue is that the speed is jumping all over the place then it is likely the resistor. Hence "speed controller". However, if OP is going to pull the blower it would probably be better to just replace the whole assembly to be sure just like in your case, so I guess unless you are really strapped for cash my argument is invalid...
My E46 was doing the exact same thing as OP's car. All I replaced was the resistor and had no more issues all the way up until I sold the car.
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No, my test proved the brushes on the blower motor were worn to the point where inadequate contact to the amature is being made. tapping on the blower motor or disturbing it will cause the brushes to make contact for a short time. If you replace the blower motor, you get the speed controller with it.