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Unread 08-08-2010, 06:28 PM   #16
Cuder
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Also tapenick, did you get a new plastic fan switch connector at the dealer?

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Unread 08-08-2010, 06:56 PM   #17
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Originally Posted by tapenick View Post
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.

Tom
It's also worn motor bushings...
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Unread 08-08-2010, 07:37 PM   #18
tapenick
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Dang! I missed that faq. Sounds like the motor may not help. Oh well, I just finished installing.. think I'll see if it helps.

The 'repair kit' for the connector is supposed to be here Tuesday.. I'll update then.


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Unread 08-08-2010, 09:10 PM   #19
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Amazing.

Is everyone having this problem? seems like it.

the problem just crawls from one component to the next. I will go to Jeep dealer tomorrow and get the specs on a TJ blower motor specs if i can. See the current draw, take mine out, hook it up to +/- 12v and compare.

What a pain...

and yes, the voltage only goes through the resistor when on Lo/m1/m2 but it would be nice to know if it is my fan before i replace it. Sure, maybe it is the relay but the same repair 2 months ago my mechanic put in a new resistor, new fan switch and new relay but who knows what the extra current could have blown out again.
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Unread 08-12-2010, 08:01 AM   #20
tapenick
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Got the repair kit yesterday... consists of:
five pieces of shrink wrap
five decent size leads (14 guage?) with crimps
five smaller leads with crimps
new 'housing' for all the connectors

crappy description.. attaching pic.

The leads are ~ 18 inches long.. thoughts on whether I should snip out as much of the existing wire as possible or as little?
jeepblowerswitchconnectorrepairkit.jpg  
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Unread 08-12-2010, 08:12 AM   #21
Cuder
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Have you read this thread?
http://www.jeepforum.com/forum/f9/fr...w-pics-579700/
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Unread 08-12-2010, 09:02 AM   #22
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Allot of people are dealing with this. I have replaced a couple switches, repaired melted wiring harness and everything is working know how ever I went to AutoZone to get a new lifetime warranty fan. I am to impatient to wait for one to be shipped. I installed the new fan, it was noisy and either ran backward or not fast enough to push much air threw the vents. I will get another fan (warranty) and install it tonight. Hope it works.

The old fan still works fine but with all the discussion about it wearing and heating up wires I am replacing it. I may also do the relay fix too. I have a dodge that supposedly has the same issue. It is newer but the fan started making noises so I will replace that one too, before I have to start replacing more switches and wiring harnesses.

I suggest anybody having these issues replace your blower and/or do the relay fix.
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Unread 08-14-2010, 08:36 PM   #23
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Update - replaced the connector.. still no fan. Check fuses, good. Even though it wasn't even working on high I went to check the resistor .. found the attached pic.

Question is, why wouldn't it work on high?
resistorconnector.jpg  
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Unread 08-14-2010, 09:32 PM   #24
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Man, you are melted everywhere.
Did you look at the connectors beside the mode selector, on the right side?
The one with the arrow pointing at it, under "this switch here".
It melts also, making the termials lose contact.
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Unread 08-15-2010, 06:06 AM   #25
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Originally Posted by tapenick View Post
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
Yep, this is a two fold problem and both work together to screw things up. Undersized wires and worn blower motors are the culprit. First the blower motor start to show its age and when it does it wants to pull more current through those undersized wires. That along with the crappy idea of using a 5 amp switch to control a 30 amp blower motor is just stupid. Install a 40 amp relay in the circuit so now the switch controls the relay which in turn controls the blower motor and you have fixed JEEPS screw up in design.
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Unread 08-15-2010, 06:09 AM   #26
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Originally Posted by tapenick View Post
Got the repair kit yesterday... consists of:
five pieces of shrink wrap
five decent size leads (14 guage?) with crimps
five smaller leads with crimps
new 'housing' for all the connectors

crappy description.. attaching pic.

The leads are ~ 18 inches long.. thoughts on whether I should snip out as much of the existing wire as possible or as little?
Back to using the undersized wires again I see. Without the relay mod you will be back in the same boat in a few weeks.
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Unread 08-15-2010, 08:19 AM   #27
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Originally Posted by JBTJ View Post
Back to using the undersized wires again I see. Without the relay mod you will be back in the same boat in a few weeks.
Yep, planning to do the relay mod when I get it back going.


Quote:
Originally Posted by cuder View Post
Man, you are melted everywhere.
Did you look at the connectors beside the mode selector, on the right side?
The one with the arrow pointing at it, under "this switch here".
It melts also, making the termials lose contact.
I took a look at that 'other' connector because I saw another thread where it was melted. Looked fine.. I didn't unplug it and inspect closesly though. I've put the dash back together.. guess I'll see what fixing the resistor plug buys me and go from there. Unless there are other ideas?!?!?


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Unread 08-16-2010, 10:00 PM   #28
tapenick
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Quote:
Originally Posted by cuder View Post
Man, you are melted everywhere.
Did you look at the connectors beside the mode selector, on the right side?
The one with the arrow pointing at it, under "this switch here".
It melts also, making the termials lose contact.

Cuder wins the prize.. well maybe. Replaced the resistor connector tonight.. still nothing. Pulled the dash again... that connector on the right side is melted. Anyone know what that's called?
otherconnector.jpg  
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Unread 08-17-2010, 05:37 PM   #29
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Any idea what that switch / connector is called? Went to the Jeep place today and they could not find it.

If not, thoughts on rigging one up? I probably should have done that on the other two and saved $90.


Tom
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Unread 08-17-2010, 06:39 PM   #30
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Look for one at a wrecking yard.
I got one from a parts guy at a dealership, he said he cut the whole end of the harness off every Jeep he found at the wrecking yards because he had seen this problem so much.
I gave him a 12 pack of Coors for it.
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