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I have a 2008 Ram. Twice this week I turned the heater on and smelled smoke thru the vent. It smelled like something electrical burning. I've experienced this before with my 2002 Dakota. On my Dakota the heater resistor burned up. I installed a new one and the same thing happened again; this time it melted the wiring harness. Finally, third times a charm, I replaced the resistor, wiring harness and fan blower motor. All is well now with the Dakota and I fear I'm going down the same path with the Ram. I really don't want to just replace all of these parts if I don't need to as the cost is expensive as you can imagine.

Questions...
Am I on the right path?
If the harness is OK, should I go ahead and replace both the resistor and the blower fan?
How can I test the parts for what may be an intermittent short?
Am I the only one to discover that Dodge has crappy heating components?
 

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I have seen this with older Dodge Big vans. The cause is the wire size at the resistor block. To cure it run #12 gage stranded wire for one foot from the resistor. Then slpice to the old wiring. This acts like a heat sink for the system.
 

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Wire probably got hot. hot wires carry less current, low current tears up electric motors, Everything these days seems to be overengineered, more with less. If you can, use bigger wires, I venture that carbuilder has this ? 100% correct.
 
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