Blower resistor repair

That is not a legitimate repair. As a TV/VCR repairman, we always dug down to the individual components and replaced the defective ones, but in this case, you are guaranteed to have unsatisfactory results. First of all, you will find the fuse was spot-welded to the terminals. Solder will melt in this application, and if you just twist wires together, those connections will degrade from the high heat and the high current. The last thing you want is a spark being created where leaves, mouse nests, and other debris collects, and air flow is fanning the embers.

Resistor assemblies are not that expensive, and they are far more reliable than the pulse-width computer-controlled systems the insane engineers use today. You should feel lucky to have such an inexpensive and reliable system in your truck.

Also be aware that fuse burned open because the fan motor has tight bearings, so it must be replaced too to prevent a repeat failure. It is true these fuses have a temperature rating, but it is that excessive current that burned it open. Thermal fuses are specified by the engineers to match the requirements for the application, and as such, the fuse manufacturer typically makes a special run just for the car manufacturer. Those fuses you can buy have generic ratings that will not match those used in the specialty applications. I would be very surprised if you could find a replacement that matches your needs.

I must add one more word of warning. You would be surprised what insurance investigators can uncover. If there were to be a fire in your truck, regardless of the cause, they will find any modified or non-standard parts. I understand your desire to fix what you have, because I do the same thing whenever possible, but given the extremely low cost of this assembly, your time is worth more than what you might save. If I have not convinced you yet, understand that any professional mechanic caught trying to do this type of dangerous repair on a customer's car would surely be fired on the spot. No business owner wants to risk a lawsuit when it is so easy to avoid. Let the resistor assembly manufacturer and GM take on the liability.