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3rd Gen Ram Tech2002-2008 Rams: This section is for TECHNICAL discussions only, that involve the 2002 through 2008 Rams Rams. For any non-tech discussions, please direct your attention to the "General discussion/NON-tech" sub sections.
sounds like, by the process of elimination, that if as soon as you replaced a resistor it started making a burning smell, and the resistor smells exactly like what the air blowing out smells like it's pretty safe to say that it's the resistor. as far as a break-in period, i've never heard of one. you may have gotten the wrong part or a bad resistor. also, you might want to think about what blew the old resistor.... maybe this new one is just strong enough not to blow and the old one wasn't. you may want to test the volts and amps going into the new resistor. my .02
When I removed the old resistor and looked at where the plug connects onto it, it looked corroded. So the first resistor I bought said it was for Blower Motor W/Auxiliary AC. I went & picked up the correct resistor without Auxiliary A/C and it seems to be working fine now. I ran the a/c on all the fan speed setting, for a while on each setting, & no smells have come out the vents. With the 1st resistor i started to get the smell right away.