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Unread 08-04-2010, 10:20 PM   #1
tapenick
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fan switch connector

2000 TJ
A/C fan only worked on low (1) .. replaced the fan switch, worked on 1,2, and 4. Then, it died completely. NO fan. Disassembled tonight and found this mess:



Any ideas what would cause it to get that hot?
And how to proceed on fixing this mess?


Tom

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Unread 08-04-2010, 10:37 PM   #2
Cuder
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The brushes in the blower motor wears out and puts to much current through the wire that are too small. Models around 2000 are the ones that this happen to most.
There is a mod somewhere on here to put relays on the wires to solve this problem. I have been just sweating it and keeping the A/C on 1 or 2.
The three wires on the right are also known to melt.
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Unread 08-05-2010, 06:20 AM   #3
Knuckelhead
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The blower motor bearings wear out also...
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Unread 08-05-2010, 04:10 PM   #4
tapenick
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Guy at the Jeep place said to check for a resistor being grounded too. Somewhere near the fan motor. Guess I have some investigating to do.

Can purchase a replacement harness for the blower switch connector that just unplugs.. $38. But get this - if it's the fan motor causing the current draw - new motor is $267!!!


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Unread 08-05-2010, 07:43 PM   #5
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Quote:
Originally Posted by tapenick View Post
Can purchase a replacement harness for the blower switch connector that just unplugs.. $38. But get this - if it's the fan motor causing the current draw - new motor is $267!!!
Rebuild the fan motor...
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Unread 08-05-2010, 07:53 PM   #6
Cuder
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$ 49.09 plus shipping. $10.60 4-7 days to ship to Dallas
lifetime warranty
DirectAuto.com - 1997-2001 Jeep Wrangler Heater / AC Blower Motor
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Unread 08-05-2010, 08:57 PM   #7
tapenick
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Fourty-nine bucks.. now we're talking! Thanks cuder!

Been reading some threads about the resistor ... but since mine does not work on high that's probably not my problem, right? Guessing it's just that mangled up connector.

Blower motor is right behind the battery.. looks like a no-brainer?


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Unread 08-05-2010, 11:19 PM   #8
Cuder
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There is a relay mod in this thread at the end. I haven't done it yet.
http://www.jeepforum.com/forum/f9/fr...w-pics-579700/

Here is some more on this problem.
http://www.jeepforum.com/forum/f9/he...switch-692735/
http://www.jeepforum.com/forum/f9/he...-fuses-962112/

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Unread 08-07-2010, 11:23 AM   #9
tapenick
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Okay, the part the Jeep place quoted me was the vacuum connector for the defrost/vent control. Ugh. But, the parts guy did some digging and found part number 68052589AA which is a 'repair kit' for the blower switch harness. (sounds like a pigtail) $42.17. Guess I'll order it, slap the new blower in today, then hope it's the right part.

Interesting article on this topic:
Jeep Fire Prevention - Jp Magazine


Tom
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Unread 08-07-2010, 10:56 PM   #10
tapenick
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Okay guys - we have a local guy that deals mostly in used Jeeps (Used Jeeps For Sale - Gilbert Jeeps and 4x4's) ... swung by there today and he was intimately familiar with my problem. But, he said that the motor wasn't causing the problems.. that the wiring was just insufficient and over time started causing problems. I'm having a hard time swallowing that.. wanted to check with the group. In his defense.. he fixes a lot of them and sends the folks on their way... so may not know if it breaks again.

Do we have a consensus that the motor is probably going bad causing extra current draw?


Tom
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Unread 08-08-2010, 05:35 PM   #11
wushaw
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[Quote] Do we have a consensus that the motor is probably going bad causing extra current draw? [Quote]

Well the motor has moving parts right? Moving parts do wear out right? Do wires have moving parts?

And if the wire guage was at fault then they would have failed sooner than 8 - 10 years down the road.
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Unread 08-08-2010, 05:57 PM   #12
invishand
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Why dont the fuses work?

why dont the fuses work by burning when the current of the old motors is drawing more than the wires/connectors/and switches can take?

Two moths ago i repaired a melted AC/Htr master on/off electrical switch (not the vacuum switch attached to the same right-most knob) and today, the connector melted to the Fan Speed Resistor behind the glove compartment when i had in Lo position for 15min. The ac works great but fan only works in HI position again. Here we go again... I am now assuming i have a huge current drain being demanded by the old fan. Anyone recommend the best way to get the actual dc current being drawn by your fan without taking the battery and fan motor out?

My mechanic found and fixed the first issue but i did the research this time and all sorts of melted connectors, switches, and wires all through the e- supply to the fan.

See schematic @
http://www.jeepforum.com/forum/f11/d...re-fix-580627/

And does anyone have a fuse block diagram that shows which fuse is the blower fuse (shown as 30a in the schematic)?
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Unread 08-08-2010, 06:44 PM   #13
tapenick
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That's what I was thinking. Just took the old one out.. no signs of anything wrong with it. I understand that worn brushes probably wouldn't be detectable.. just going to slap the new one in and hope for the best.

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Unread 08-08-2010, 06:57 PM   #14
tapenick
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Nothing in the resistor pack could cause this could it? I wasn't thinking so since, from my understanding, the circuit doesn't go through the resistor pack on high.

Tom
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Unread 08-08-2010, 07:23 PM   #15
Cuder
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I would do the relay mod too. I am when it gets cooler out. I have been leaving it on settings 3 and 4 no longer than 5 min, then going to setting 2.
I have read about others that replaced the blower motor and still got melted switches.
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fan switch , connector , replacement , fix , tj , wrangler

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