Got it! Okay, sports fans, this is flat country, and probably applies to most rangers. I found a post from a Ford tech saying there could be a big problem where the resistor positions start to disappear (hence you lose the fan speed position). This problem is that the fan motor becomes very resistant over time and is or could be the cause of the resistor failure, which was the case in my case. So if you just change the resistor when you lose fan speed the new resistor can just blow up which I've heard from a lot of people saying the new resistor doesn't last long. So the moral of the story is, if you start to lose fan speed position, it's best to swap out all relevant components. Resistor, new wiring harness, fan motor and selector switch. These were all Original Equipment parts on a 2005 FX4 4.0 with 215,000 miles so I definitely used them well past their expiry date. All the parts are around $100 for everything except the BM which they wanted $160 for.
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