I sometimes get chastised "Flatter than Hammered Sh*t" for embracing explanations considered Way Over The Top to suit certain explanatory situations. But most of the time when that happens... there is a
SAFETY ISSUE at the Heart of My Thinking and Concern about these things.
THIS is one of THOSE Times:
It is Extremely Important to Understand all that follows:
(1) The Fine Dust around ALL of the Objects, Parts, Components, Devices and Electrical Wiring and Connectors shown inside of all your Photos... indicates that your Local Environment is one that is plagued with Desert Sand Storms and/or Driving Repeatedly on Bad, Bumpy Roads.
That Dust can gradually wear down the Contacts Between Connectors and Connecting Devices.
(2) These Environmental Issues DIRECTLY relate to this present problem of Melted Connectors on BOTH sides of these Components due to Excessive Vibrations and the Presence of Fine Abrasive Particles invading these Electrical Connections... causing Physical BREAKS in Electrical Conduction within ALL of these Non-Solid State Connections.
(3) This implies that there is a PHYSICAL PROBLEM OF RAPID CONNECT-DISCONNECTS WITHIN THE MATED CONNECTORS AND THE DEVICES and Invite
RAPID ELECTRICAL ARCING IN BETWEEN THEM.
(4) In the Absence of having Solid State Connections ...this means
Soldered and Shrink Insulated with Sealing Glue as an Insulator...
ANYTHING that is inside of your Vehicle that uses a
Press Fit Connectors married to Connections with Motors/Relays/Radio, etc., will suffer these events after being exposed to
Frequent Vibration Disturbances within Dust Invaded Electrical Connections.
(5) The Locations where these Electrical Arcs occur are PLACES OF EXTREMELY HIGH TEMPORARY ELECTRICAL RESISTANCE that will eventually ARC at Very High Temperatures sufficient to Melt the Plastic Housings around these Connectors and Short Circuit them with Sparks and Flames resulting under the Dashboard (Unseen) from the Melting and Burning Plastic catching Fire... or igniting OTHER Flammable Objects nearby. These problems can occur...before a Fuse or Relay can interrupt the Circuit!
(6) "Bad Vibrations" can become accentuated in Vehicles where the Connectors are only 'casually' plugged together and NOT Zip-Tied and Secured so they Do NOT Swing and Move Back and Forth...Un-Tethered. The other more 'pressing' Vibration Culprit will be having VERY BAD MOTOR MOUNTS. This condition can be discovered if you can see any "Sticky Black Gel Goo" pasted on the Wheel Well areas adjacent to and underneath the Lower Motor Mount areas. This happens when the In-Dwelling Gel leaks out after being Pounded to Death and pouring, squeezing then squirting out under pressure through Cracks in the Motor Mount "Rubber Bulb" Carcasses.
While this Video involves an Exemplar Circuit for a Common Canadian Housing Construction Wiring Safety Issue... The PRINCIPLES are IDENTICAL with what is occurring inside of your SUV.
What happens during this Video is EXACTLY what has happened inside of your SUV to Short Circuit and Destroy the Blower Motor Connectors/Connections and ELSEWHERE...but perhaps NOT as yet Discovered within OTHER Modules and Devices inside: