AC Control wires hot/melting plastic behind dash

Sub'd

 

If you need help let me know.

 

90980-11615 is the connector part number.

 

Nice! When I went to Toyota they told me I had to order the entire harness and said that you can't buy that part. I was able to fix mine as it wasn't melted as bad as some of the other people who have chimed in.

 

I wanted to replace the terminals on mine but couldn't find them. Toyota had them but with a wire crimped on. I put some electrical tape on the burn wire insulation, cleaned all the burnt plastic off the existing terminals, bent the metal tab in the terminals for a better connection and popped them in the new plug. The junkyard control works great. I did notice the plug in the blower motor resistor was getting brown too. How do you remove the pins in that? I messed with it for a bit last night but couldn't extract them to bend it for a better connection.

 

I haven't tried but most of those connectors have some type of flap that needs to be depressed to release the pins. A super small flat head screwdriver might work.

 

I've got this exact same problem (AC blower doesn't work on high). I replaced the resistor and motor before I pulled the dash plug and found the same pin burned like the OP. You mentioned soldering it? Are you just removing the plug from the harness and soldering each wire directly to the pins in the back of the AC control panel?

 

I add solder to the flat tabs so the connectors would sit nice and tight. Someone mentioned the reason it melts is because the connection is loose and wiggles a bit on the connector. Since I added solder to the flat parts and just pushed the connectors back on they have been great in 3 different tacoma's I've done this fix on.

Mine I ended up having a buddy who totaled out his truck and I cut out most of his harness so I could use that. I still added the solder to the flat parts to make sure it wouldn't happen again.

Edit: The next one I fix I'll take a lot of pics and make a write up.

 

Good idea, I'll try that. Thanks!

 

If you have any questions or run into other issues PM me and I'll help you out.

 

Same issue on 2006

 

Thank you, that makes complete sense. My 06 has 250,00 miles behind it so I expect so weird things to pop up.

 

You can buy the actual tool at most HVAC places for a few bucks, they work GREAT.

 

This is exactly what my unit looks like. 2013 gen 2. Fan was not working correctly,start , stop, took it out and the same blade on the connector was burned and the switch was scorched. Just had blower motor an resistor replacedthis summer. Looks like a design problem. What has everyone found to be the solution and replacement fix.

 

I'm wondering if a small dab of Alnox electrical joint compound in each connector would work to decrease resistance and afford a tighter fit. [fine ground aluminum in suspension]

 

I think it would help if you added it before the issue happens. Once it starts to melt it goes to hell really fast.

 

This is an old thread, but I put solder on the connector and it fixed it for now.

 

Anybody have any tips for replacing the connector housing? I ordered and received the part from the dealer, but am now just trying to figure out if I can disconnect the pigtail from the burnt connector and reconnect the new one or if I need to cut and splice each one individually.

 

I have this kit and I just unpinned each wire and put them into a new harness.

$9 Maerd Terminal Removal Tool Kit 76Pcs Electrical Connector Pin Removal Tool Terminal Ejector Kit Depinning Tool for Automotive Car

https://www.amazon.com/gp/product/B08LQG4YHN/ref=ppx_yo_dt_b_asin_title_o00_s00?ie=UTF8