Dodge told me that this issue is so common that they keep the parts in stock. Did you have fun trying to figure out how to disassemble the plug assembly, insert the green or purple wires, and then reassemble? Heat means resistance, so something perhaps further up the wire is pulling excessive current.

 

Dodge makes a replacement harness that takes care of the issue. You have to cut the old harness off and replace with a newer heavier duty one and I think it also comes with a new resistor. Remember to solder all connections and shrink tube them.

 

I used the green wires and not the purple. The green wires are 10ga. and not color coded. The kit included heat shrink tube as well and I own a heat shrink gun.

 

Thanks guys! I appreciate the help. Will call Dodge after Irene passes!

 

That just read wrong. It read like your wife Irene was sick and you were waiting... then I remembered the little hurricane.

 

Replacing the resistor and the wiring connector resolved the problem. Now the heat wave is over It's all thunder and lightning, so I'm not driving anywhere anyway. I've got to tell you that the day I did the work was HOT. It took me 2 hours to snip off a connector and replace the 5 wires. I just could not get my hands to work. Considering that I am an electronics technician this is stupid! But alas, it is fixed in time for winter. I chose to use the larger gauge wires and the brass crimps in addition to soldering the wires together first. I then heated the brass and melted the solder through and through before heat shrinking them. I understand from Dodge that this is such a common problem that they regularly stock the parts.

Thank you for your help.

 

Ok I have a 2003 Durango and have also replaced the resister fuse 8 times over the past 10 years. My problem now is that the fuse is doesn't want to stay screwed in. Any suggestions on how to fix this? After 10 years of ownership and only 127,000 miles I'm not ready to give up on ol' blue!

 

I have a similar question.
I'm driving a 99 Durango with the 5.2 liter.
My fan has completely quit working, so if it is the resistor, I'm unable to find it.
I even removed my glovebox and still do not see it anywhere.
All I was able to find was a small vacuum line on the bottom right, right next to the "A" pillar.

Is it possible that on some models the resistor was placed in a different location?

 

the pre-2000 models the resistor went into the firewall from the engine bay side, under the cowl iirc, im not 100% sur where, you will have to check w/ someone who owns an early model

 

Yes it's in the intake in the cowl (outside below the windshield in the drainage more on the passenger side).