Did you know that running your blower motor on high shortens the life of the motor? Not only that but the A/C actually blows colder at a lower speed and the heater blows hotter because the air is passing through the heater core or evaporator at a more leisurely pace for better temperature control. Use the next lower speed if you want more airflow but less electrical stress on the system.
The blower motor draws the most current on high speed. This sample was a new blower on high. 8-9 amps draw.
As the blower motor ages (wears out) it needs more current to maintain high speed.
The demand on the system causes circuits and connections to be stressed to the point of failure. The resistor may fail but the failure is due to the blower motor wear. The connectors may melt but the failure is due to the blower motor wear.
The repair will have to address both the cause and the effect.
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