2nd gen blower resistor questions

Just bought my 2006 DC Sport....the fan worked fine on all settings except low...on low speed you had nothing.
So I just ordered the dorman replacement kit from Amazon with the resistor and new harness...
When I went to replace my harness I noticed it had what looked like a new harness (dated 2015). It had already been replaced..I could not see any burn marks on the wires or the harness....matter of fact it looked identical to the new one that I just bought....
So I replaced just the resistor....when I pulled the old resistor out I noticed several burnt spots on the board....
So.....when I put in the new resistor I cranked up to try it before screwing it back up into the hole (it was a pain getting to the screws)....
Ran it for a couple of minutes and it was fine....but I noticed after cutting off truck and getting ready to screw resistor up into the cavity that it was hot....
I went ahead and screwed it back in. Then when I went out for drive last night, the fan blew on high speed on all four settings!
Got back into truck this morning and it worked fine again....
Questions....
1. Is it normal for resistor to get hot?
2. Could the harness still be the problem?
3. I noticed a couple of the pin connectors move around in the grey harness...but don’t look burnt.....
4. Or is it a different problem?

 

1. Yes
2. Most reported problems are with the connectors, not the harness
4. On my truck, the problem was a loose connector at the blower.

 

Resisters get hot since they create electrical resistance hench why they get screwed into the airstream of the ac case.
If the terminals are not tight I would replace the connector.

 

Sorry. By saying harness I am talking about the female connector that came in the kit....
But if there is no burnt marks or signs of heat how can that be the problem?

 

So the resister had little bits of metal sticking out that are male pins, the harness connector is connected to the vehicle wiring and has female metal bits that should not move around in the connector, if you really push they will move some but by gently shaking the connector they should not move, if they move or are not tight they will not make good contact with the male pins on the resister which was likely the original problem, as such since you have a new resister and pigtail kit for the harness I would cut and splice the new pigtail kit in so you dont have the same problem down the road.

 

Had the same issue with my 07, kept messing with the connector and it would work for a while then crap out again. I ordered this

$32 82141-04M40

https://smile.amazon.com/gp/product/B00TNNSWNC/ref=ppx_yo_dt_b_asin_title_o07_s00?ie=UTF8&psc=1 solder the wires together and haven't had a problem since 2017.

 

OP, the original green resistor will get so hot it will immediately burn your skin off.

The likely cause on yours is the OEM connector. It is actually a General Motors special; in fact our entire HVAC system is GM. The contacts in the GM connectors have low tension and do not always show show signs of burning but their contact force with the male pins is typically too low and creates higher resistance. So you will get all manner of problems at the connector ranging from erratic operation to burning.