Heat will build up if there is any corrosion on any of the connection points. Possibly one or two of the quick connects on the plug had some corrosion build-up over the years. When that position was selected the corrosion became a point of high resistance to the flow of current to the motor which caused the plug to heat up and melt. Glad to see that you got the problem detected and resolved. Thanks for sharing...

 

Hey guys,
so i bought new resistor and cut the wires, but I don't know which order it went. I've got light green, dark green with white strip, blue, and maybe a tan?
any help would be appreciated. - Greg

 

Why would you cut the wires? Isn't there a plug for the resistor block?

 

Sorry, forgot to mention, old connector was melted, along with the resistor. I bought both resistor and new connector. I cut wires off old connector months ago and can't remember the order.

 

When it comes to electrical, sometimes you gotta' re-start with all brand new parts. And also a brand new heater blower motor resistor purchased from NAPA turned out faulty from the get-go and it was tested with my trusty but not dusty Simpson XLPM 260 analog multimeter that's been used from the 1970s and recalibrated recently by an analog shop. Once upon a time NAPA offered the best parts hands down but no more. 8(

 

Go here, and look up the wiring diagram you need.