The right way to fix the infamous Heater Problem!!!
I am resurrecting this thread just in time for winter. I have been thru 3 switches and one resistor pack. I was thinking about doing the relay fix as posted in JP Magazine but ended up with this instead. I bought a new switch for around 15 bux. If your fan switch keeps going out and you have already replaced your resistor it IS the blower motor itself is worn and is taking many more amps to turn it. Which in turn heats up the wiring and melts your switch.
I installed a new blower motor last night, and it took about 15 mins. Remove the battery and computer and its right there. After i got it all back together i let the fan run for about an hour. End result, this switch never became hot whatsoever. When with the old blower motor the switch would melt within about 10 mins. I recommend changing your blower motor if you experience burnt wires and that burnt electrical smell. You can pick one up on ebay for $49.99 shipped.....better than paying $140.00 at your local parts store. Putting in relays is not the answer and is not the right way to do it. I just figured id share since i know what a PIA this problem has been with TJ's. I hope more people can benefit from this.