Well, I'm not sure what or why I'm having this issue again, but earlier this summer I replaced both a bad blower motor, and the resistor and plug. I knew the resistor was going bad, the motor finally died, so I replaced those, and the plug burnt out on my new resistor, so I replaced the resistor and the plug, and everything has been fine until this morning. The fan cut out and wouldn't come back on, so I removed the resistor and found this lovely little present from life:

<a data-flickr-embed="true" href="https://www.flickr.com/photos/16134441@N06/23617672819/in/dateposted-public/" title="Blower motor resistor and plug burnt out AGAIN!!"><img src="https://farm6.staticflickr.com/5797/23617672819_08f37a9bbb.jpg" width="375" height="500" alt="Blower motor resistor and plug burnt out AGAIN!!"></a>

<a data-flickr-embed="true" href="https://www.flickr.com/photos/16134441@N06/23877279842/in/dateposted-public/" title="Blower motor resistor and plug burnt out AGAIN!!"><img src="https://farm6.staticflickr.com/5719/23877279842_628013d5ce.jpg" width="500" height="375" alt="Blower motor resistor and plug burnt out AGAIN!!"></a>

So this leaves me with the question of what do I need to do to fix this properly so I won't be having this issue again? Unfortunately this is sort of an emergency repair, being winter with a high of 16º today, I do need my heater and defrost. Thankfully I DO have working heated seats, but that does nothing for the windows or my feet...

 

Well, first, I didn't intend it to post such HUGE pictures, I didn't notice the size selector to select the size of image I wanted to embed via Flickr, I have that fixed now.

And second, the OEM kit arrived, and I cut out the last plug I installed right above where I soldered it in, stripped back the wires on the harness and soldered the new ones in. I used the gold plated terminals, rather than the tin ones. Its working, but I still am uncertain of how long this fix will last, I was hoping someone would have had some input on the issue... My dad suggested that it just shouldn't be always run on high, I don't ALWAYS use high speed on the fan, but I do use that speed more than the other 3. I'm just worried there might be some other type of issue that may be causing this, and if I don't find it that this may happen again, and it really isn't a very fun place to work in with a solder gun.

 

usually the burning is caused by poor contact in the plug (imo) or a motor going bad and pulling too much current (what most people suspect) either case would increase the resistance in the circuit and pull extra heat through that connector causing it to burn up like that, if it happens again in short order i would replace the fan again (sorry )

 

I'd agree with what shrp said about the blower possibly drawing too much current.

 

I had the same problem just replaced the blower and got a new wiring harness and haven't had any problems since

 

Yeah, run it on Medium high and see how long it lasts.