[ColoradoCole]

Problem: Blower motor pulling to many amps and burning and melting wiring harness, pigtails, and switches.

Fix: Replace Blower motor fan with nothing but a Dealer OEM Part. Possible pigtails or new wiring harness. Add in Relays to prevent future problems from happening.

Relay Walk Through...

Relay terminal #85 - 12v Power Source from Batt.

Relay terminal #86 - low speed cut wire (from fan switch)

Relay terminal #87 - low speed cut wire (to resistor block)

Relay terminal #30 - ground (new 12 gauge wire)

Repeat this step for each fan speed wire.

[TheBoogieman]

I missed the tech question.

[ColoradoCole]

NO tech question just a simplified fix instead of searching through 500 pages of useless and wrong info to find the correct info in someones post.

[Rubi4MyMrs]

That’s it for the relay configuration. You can piggy back the 12v wires to each 85 from one source since only one relay will be closed at any time. (∩∩∩∩) Also not a bad idea to use a heavier wire (12g) from the resistor to each relay’s 87 terminal since you are using a 12g wire from 30 to ground. That will help reduce the heat at the resistor connection.

[JBTJ]

I wired mine like this and it works fine.

85 switch
30 resistor pack
86 +12v
87 ground

[EwokAdventure]

Thanks for the helpful information. I replaced burned/melted switches, rewired and soldered new connections, and everything is now working as it should. My next step is to wire up some relays to prevent future issues.
As some other JeepForumites have mentioned, it has been difficult to find a clear diagram of the relay modifications, and this prompted me to draw some of my own.

I started with a fuzzy schematic that I found elsewhere on the forum (attachment: Jeep_HVAC_schematic.jpg) and I redrew the stock switching configuration for clarity (attachment: 2000_TJ_HVAC_Stock_Diagram.png).

Based on information from JBTJ, ColoradoCole, and others on the forum, I drew a diagram showing the modified relay switching configuration (attachment: 2000_TJ_HVAC_Relay_Mod_Diagram.png).

Let me know if I've missed something or made an error, and I'll correct the drawing and re-upload.

Thanks again for all the assistance and information.