Just short of 170,000 miles my AC quit blowing, I looked everything over, took out the motor and couldn't find anything wrong except for the connector wouldn't come off no matter how hard I pulled, I remember reading somewhere that the blower motor circuit can get hot and burn through the wires and blower. The connector didn't look burned or anything from the outside but once I cut it off ripped it apart, it was completely melted inside on the positive leg. I ended up stripping out the wires and soldering and heat shrinking the wires together and its back in action. Hope this can help someone with the same problem.









Now a few questions..

What would cause the circuit to be able to get hot enough to melt the plastic at the connector and not pop the 30A fuse? Also is this the correct way to fix this, whats preventing something in the circuit from not being burned up again in the future?
AC Blower motor connector.

 

The blower itself, I'd remove the blower motor, remove the two torq bolts that secure the motor to the housing, and you'll either find some nasty rusty looking bearings or lots and lots of lint/fuzz/grime. I've had good luck with lubricating the lower bearing with a good penetrating oil/lube, and re-installing it.



Or you can get a Made in Canada replacement from Rock Auto for 35-50.00 (99 blower mounts the same but has a different plug, since you cut yours you can save a few bucks and just cut/splice it or get the later style for a bit more).


The blower connector is a critical part of any vehicle, but I've seen countless manufacturers put in connectors that can't handle the load and eventually they all melt. I had the white connector near the blower on my 500.00 03 D2 do the same thing. I was able to save it, but it was due to the blower motor which was badly corroded due to water seeping into the blower housing from a leaky windshield cowl.

 

Im going to order a new one to be safe and to keep as a spare if something breaks when trying to clean and lube the old motor. Good advice and information, Thanks!

 

My daughter disliked the way the ac blower rattled the whole dash on any setting above 3 bars.

i pulled the motor out and it was packed with leaves.

i made her dump out the leaves.

i reinsralled it.

amazing!

nice quiet fan now.