It melts because of the high resistance at the poor connection. Ideally the terminal should have been replaced. It is surprising, with the number of these seen, it has not had a service bulletin. You can either get a patch harness with leads, that replaces the connector using crimp and seal connectors, you can get an HVAC extension harness, or you can get the red connector body, lock, and a new terminal to crimp on the wire.
Tuesday, March 9th, 2010 AT 10:15 PM