My dryer was running, but would not heat up. I unplugged the unit and removed the rear panel. I found one wire connected to the ‘High Limit Dryer Thermostat’ to be melted off the connector. I’m thinking this is an easy fix; trim the burnt end off the wire, crimp on a new connector, and re-attach to the original thermostat. I’m wondering, however, why did this happen? Is it common? If I make this repair will it happen again or possibly cause a bigger problem? Any suggestions or expert opinions will be appreciated.
Could be that there was a connection problem from day one.
If the connector was not properly crimped there is some resistance between the wire and the connector. This acts the same as a heating element and heats up as current passes through it. The wires start to corrode which increases the resistance which increases the heating etc. etc.etc. Till finally the connection fails.
Cut back the wire until you get to nice clean copper.
Make sure you get a good crimp onto the wire with the new connector.
Make sure the connector you use is rated for high current.
Make sure the thermostat lug is good and clean. If it is pitted or cannot be cleaned properly replace the thermostat.