Manufacturing flaw with Final Stage Resistor?
 

I am curious if you think this could be either bad luck or a serious manufacturing flaw with the final stage resistor in the climate control. I need to replace mine for the the 3rd time in 6 years...

Here's the funny and very peculiar part though. I kept a journal of the repairs I've done to the X5 and when the parts failed or problems started. The FSR has failed every two years literally almost to the day, and in the same time of day!! Check this out

FSR failure #1 July 25, 2006 - 10:15pm
FSR failure #2 July 11, 2008 - 10:50pm
FSR failure #3 July 12, 2010 - 11:20pm

Every single time it's been after 10pm and within 1-2 weeks of it's 2 year mark. I know specifically because it's happened each time when I'm getting back into the X5 after I'm leaving the gym! I honestly laughed about it last night because I was thinking it would fail at any time after a workout. I wasn't laughing this morning when I forgot I had no AC and had a wrinkled suit by the time I got into work (it's about 110 degrees today).

So do I have bad/odd luck? Is it a result of the extreme temperatures here in July? Or is it a serious flaw with the part?

FWIW - the local dealer wants $169 for the part :wow: I'll be ordering it from Autohaus AZ for $70 and free shipping - if I can wait a coule of days..

A part that costs about $5 to make and retails for $169 at the dealer and fails every 2 years is called a "money maker". Even more so if a dealer fits the thing!
Very good design criteria from a $tealer's point of view.

Is anyone savvy on the value and wattage ratings of the resistor(s)? A high-quality, low-cost replacement and weatherproof enclosure could probably be sourced through Mouser or Allied Electronics. Alternative connector/socket ends for the wiring harness could be found there as well.

On second thought, the existing unit could be gutted and internals replaced, saving the additional enclosure/wiring connector steps.

If anyone has a failed unit that they could send to me, with info on correct values/wattage ratings (color codes might be on the resistor(s) inside the unit), I could write up a low-cost internals replacement "how-to" after successful replacement of resistor(s)/testing. If you guys are (or have friends that are) handy with a soldering iron, this could be a not so hard way to save a few dollars. :)

FYI - I ordered mine from Autohaus AZ this morning for $70.14 and it shipped this morning (free UPS ground). FCP Groton also has an aftermarket one for only $45, but they're in CT and shipping takes way longer to the west coast from there (and it's not free).

I just bought one from Deutche Parts USA on Ebay for $40 shipped. I got one from them for my E36 and it works great, been in for over a year.

+1 on Autohausaz.com. My X5 resistor should get here today.

Dan

Hi , I have the same problem. Does the final stage unit fail cause the climate control fail too?
My climate control has no lite on and non of the button work. So do you think the FSU fail that cause the climate control has no function at all?
Please give me some clue. Thank

FSU is pissing me off . What cause FSU to fail?

There are instructions around here somewhere. A guy shows how he fixed it, and it still works great.

I replaced mine with aftermarket and it seems to be holding up for 5 years now. It's crap shoot.