2nd Gen Tacoma Blower Resistor Issues

I have read some forums and found this is a common issue. I purchased a cheap knockoff that ended up running at MEd-MED/LOW speed on all switch positions. I realized the OEM resistor did not look burned. The connector side of the harness was burnt on one terminal only.

I decided to replace the OEM original and now have all speeds on the correct switch position.

So the terminal burnt. Not the resistor itself. I am now looking into what others have done to either upgrade the plug end or bypass it and possibly add a secondary inline fuse.

Toyota did not mean to use the terminal as a fusible link. They also probably did not mean to have the fuse not burn in the event the terminal overheated to the point of melting the surrounding plastic. I am concerned about bypassing this altogether and melting the wire and surrounding wires within the harness.

I am down to customize, looking for knowledge and ideas.

Cheers

 

You replace the plug at the resistor and upgrade to the newer resistor.
The link I posted in your other thread should have the part # and new style connector.

 

I need to look into this

and if there’s a least PN

from what I’ve heard, you put a resistor and wiring pigtail in it. Cutting off the old and crimping on new. In the chance the wiring, not just the resistor, is also burned like you say.

 

What causes the terminal plug to burn is a loose connection in the plug usually due to a sloppy or stretched female terminal. That causes the connection to act like a heater, that is why the heating is localized at the connector.

If it were an over current condition that caused it the fuse would blow and the entire wire run would show indications of over
heating.

 

I ordered this just yesterday. After extensive digging, this OEM updated unit apparently resolves the issue with the old terminals. Note the wire colors though when splicing in the replacement. Connecter B4 is the style that’s in your truck now; the square B16 is the replacement.