1999 Chrysler Voyager. The 21 pin plug at the back of the HVAC melted in the corner where the earth wire is positioned. Months later and car less I manage to find a replacement plug and spliced it together using dominoes which after only minuets running also melted the plastic connection for the earth. Any suggestions? I was thinking changing the control panel/motherboard as perhaps that is where the fault is. The wire melted on the control panel side of the connection while the wire on the other side of the domino was OK. I hope I make sense, can you tell I am no mechanic! please be gentle with me, I have to fix my car and really could do with some help.

 

With the heater off the connector does not get hot and seemingly is OK but once the blower heater is on the plastic starts to heat and melt.

 

I use to buy a used connector from junk yard , beware year 96-97 is diffrent compare to 98 and forward.

I use to solder an extra wire on the this hot ground wire and bolt it to the metal behind the HVAC panel . It becourse over time the ground around the car gets bad and another thing is the rear wiper gets stuck and draw a high current through the connector in HVAC . So if you change the connector and make the extra ground behind HVAC panel . and take apart the rear wiper gear clean it and lube it you will be fine. Or just disconect the wiper will solve it.

 

maybe your HVAC blower motor is stuck , it's quit easy to undo and spray some WD40 or equal on the shaft bearing or just buy a new blower motor .