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Unread 02-20-2009, 06:31 PM   #31
kazafka
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Please either upload to the post or send to alex@professionalheadshots.com thanks in advance.

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Unread 03-19-2009, 11:24 PM   #32
03GreenSahara
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For those of you having issues replacing the resistor: I recently had to replace my resistor as well and had a hard time w/ the plug even after taking out the red lock. I ended up unscrewing the resistor and taking it out. At that time I was able to get the plug off as it has enough wire to hang down under the dash and much easier to get ahold of.
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Unread 03-22-2009, 11:26 PM   #33
Bullshark
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i can't see any of the pics. I am registered. Were the pics taken off?
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Unread 03-23-2009, 02:13 AM   #34
Jonny Jeep
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Here's a link with write up and pictures.
http://www3.sympatico.ca/fm.mjb/Resistor.htm
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Unread 03-26-2009, 01:15 AM   #35
Bullshark
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worked for ~15 seconds

Ok so I got the resistor from the dealer for $45. The cheapest I could find online was $41, but i figured the shipping charges will be about $4 if not more..

So I managed to take out the old one out (it was all rusty and some leaves stuck in it) and replace it with the new one. I thought I would give it a try to make sure it works before screwing it back in. The resistor was dangling so I could see it.
I started the car and turned on the fan..I could see the different metallic resistors turn orange as I moved the switch. However, the highest setting on the switch did not work and none of the metallic resistors turned orange (I thought the current must be going through the insulated resistor). I moved the switch back to position 1 (the lowest setting). I could see one of the resistors turn orange and feel the heat blowing through the vents.

I thought I was good with having at least 3 fan settings working.... BUT everything stopped working after about 15 seconds. Now none of the settings work!

Do you guys think I burned the resistor out? I removed it to examine it and it looked ok. No broken wires or anything.

Any advice will be much appreciated.
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Unread 03-26-2009, 02:49 AM   #36
Jonny Jeep
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You may have burned it out, but more likely you've blown the thermal fuse. Have a look at this thread...
http://www.jeepforum.com/forum/f11/blower-motor-resistor-206575/ The air flow drawn through the fan is used to keep the resistor pack cool. The highest setting doesn't go through any of the resistors on the pack. It goes direct from the brown/tan wire going into the resistor pack to the fan. As it did work on high it might be a problem with the contacts on the connector not making good contact.
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Unread 03-26-2009, 09:21 PM   #37
Bullshark
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Quote:
Originally Posted by Jonny Jeep View Post
You may have burned it out, but more likely you've blown the thermal fuse. Have a look at this thread...
http://www.jeepforum.com/forum/showthread.php?t=206575 The air flow drawn through the fan is used to keep the resistor pack cool. The highest setting doesn't go through any of the resistors on the pack. It goes direct from the brown/tan wire going into the resistor pack to the fan. As it did work on high it might be a problem with the contacts on the connector not making good contact.
Ok so I ended up going to Radioshack and buying a thermal protector fuse for $1.50. I thought it would be worth a try before shelling out another $50 for a new blower resistor pack. I carefully cut out the old fuse and soldered in the new fuse, plugged it in and screwed the pack back into place...
here is a link with pics that describes that process: http://www.geocities.com/chmwatson/F...elink_fix.html
and Presto! It works except for the high setting. I think that's probably a switch contact problem on high.

I never should have tested it while it was dangling outside of where it screws in. The lack of a fan blowing on it cause it to heat up and burn out... live and learn..

I've read that fixing the switch contact problem is a real pain. Anyone have experience with that?

Thanks for your help. You guys rock!

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Unread 04-11-2009, 06:04 PM   #38
remington1
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guys i have read this as my fan does not work on high 00 tj, so do wich part do we actually replace?
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Unread 04-11-2009, 06:06 PM   #39
Jerry Bransford
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If it works normally on all speeds except for High and it doesn't blow at all on high, I'd guess the switch is bad. The resistor pack is only used on the lower fan speeds.
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Unread 05-08-2009, 05:25 PM   #40
AlphaTJ
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Quote:
Originally Posted by Jonny Jeep View Post
Here's a link with write up and pictures.
http://www3.sympatico.ca/fm.mjb/Resistor.htm
Thank you for posting this link, my TJ was only running in high and this did the trick.

What I pulled out looks pretty scary.....

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Unread 05-08-2009, 06:54 PM   #41
sshrrt
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Do This

Mine did the same thing. Only on HIGH(from battery) other speeds(Blower Motor Resistor) nothing.
Do This: GO to you local auto store (advance) and buy a DODGE VAN blower motor resistor. It is EXACTLY the same as Jeep TJ except its $20 cheaper Then check out my install here:

http://www.jeepforum.com/forum/f9/blower-motor-resistor-install-762372/
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Unread 05-08-2009, 06:55 PM   #42
sshrrt
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Mine did the same thing. Only on HIGH(from battery) other speeds(Blower Motor Resistor) nothing.
Do This: GO to you local auto store (advance) and buy a DODGE VAN blower motor resistor. It is EXACTLY the same as Jeep TJ except its $20 cheaper Then check out my install here:

http://www.jeepforum.com/forum/showthread.php?t=762372
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Unread 05-09-2009, 09:48 AM   #43
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Quote:
Originally Posted by AlphaTJ View Post
Thank you for posting this link, my TJ was only running in high and this did the trick.

What I pulled out looks pretty scary.....

You're welcome. Looks kind of like a nest. The Dodge van tip from nunnyabinus is worth a bump too.
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Unread 10-11-2009, 01:39 PM   #44
iCEMAN99tj
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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.
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Unread 10-12-2009, 11:26 AM   #45
iCEMAN99tj
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Update!!!! Checked the switch and wiring after two days of leaving the heat on for hours of driving (It's cold as **** here in Ohio), Neither the switch nor the wiring has any evidence of overheating. Now all i have to do is get a new top before it gets really cold
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