lets try this again - from the computer and not phone ...

 

Looks like it worked - hard to see inside the plug with the size of the image - but the plug is melted badly like the inside of the resistor.

 

That is the exact same plug, and the Resistor is burning on the exact same two prongs, and from what I could determine, those two leads feed the Blower Motor. The last time out I swapped out the Blower Motor, replaced the Plug, and Resistor, so far, no more problems. Once the Plug is damaged by an overload, such as the Blower Motor drawing too much current, if you don't replace the damaged Plug (or Connector if you prefer to call it that), and the Resistor all at the same time, the resistance caused by the burned connections, will fry the Plug and even a new Resistor. The Plug is available through NAPA, or a Online place called Parts Geek, and is Standard Motor Products #S-1768, the Resistor is Standard Motor Products #RU-380, and the Blower Motor is Four Seasons Part #75740. Don't try sourcing these parts used, they may already be failing, and you'll only find out after it all fries again.

 

Thanks Ben!

1 more question, I already have another resistor. Will the plug you have listed fit the stock resistor? It just looks from the pic, a bit different?

 

I realize this is an old thread, but this is the same issue I'm having, the resistor and motor went out, I replaced both, the resistor and harness melted out 3 times, a few months ago being the last, so I replaced the resistor, harness plug, AND the motor, and a couple days ago it started acting like its starting to burn up again. I really am frustrated and want to find out how to fix this. I'm sick of this crap, and it seems no one has any idea why its happening.

 

Bad ground?

 

My 2002 Dakota has eaten 6 Resistors, and 6 Plugs, and one Motor. After I replaced the Blower Motor, the Plug and Resistor were okay for a while, then the replacement Blower Motor started to become noisy, and Plug number 6 melted, and Resistor 6 went with it. At this point in time, I simply don't use the highest speed setting for the Blower Motor, and no more problems with the Plug, or the Resistor.

 

It doesn't seem to matter what speed gets used, the wire that burns out seems to be the one that takes power out of the resistor. I'm having to order yet another resistor and plug kit and do all this again...

 

im in agreement with HeyYou, bad/dirty ground,

otherwise a problem in the wire somewhere thats causing an increase in resistance.

 

If you're melting the part of the Plug supplying power to the Blower Motor, the Motor itself could be at fault, and not due to just a bad ground. The possibility exists of either bad bearings in the Blower Motor, or a bad Armature, or Field, causing a high current demand by the Blower Motor.