I replaced the blower motor resistor, it lasted maybe a year. Replaced it again and it lasted maybe a week. There are two wire plugs on the resistor,the plug on the right has two wires, black and green. The plug is melted at the black wire. I think I need to replace the blower motor and was wondering how involved it is.
if your blower is blowing it's usually ok. but your pig tail at the resistor has had resistence. that is why it was heating up the wire end and started to melt plug replace the pig tail and check the resistence to ground ( black wires are usualy ground) you shouldn't have any. some will create heat. when you install new resistor and pig tail add a little dielectric grease to the contacts and plug. it will keep corsion off and provide a better contact. hope that this helps.
I just pulled my blower out this weekend. Here is an okay youtube: http://www.youtube.com/watch?v=-U7T8Nb-JMI A couple important items: The back screw is a PIA - you will need a flexible extension. I did it with a knuckle - but miserable. You can't see it without a mirror - I did it by feel. Pulling the side panel out, carpet and pad back is a must. I had to tear the padding a little. The other thing is the slide or door. It will not come out - but you need to detach it from the lower cover. I used a screw driver - through the holes to pop it loose from it's swivel - connection point to the lower cover. After it is off - the rest is obvious. Good luck.
Repeated resistor failures usually mean the blower motor has worn out and is drawing excessive current. Unless you've just had crazy bad luck you are in for a blower motor replacement.
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